Laminates including a reticulated thermoplastic film and method of making the same

ABSTRACT

A laminate of an at least partially reticulated thermoplastic film joined to an extensible carrier. The reticulated thermoplastic film includes a backing with openings and discrete elements protruding from the first major surface. There are two discrete elements aligned in a first direction abutting opposite ends of any given opening. In a second direction perpendicular to the first direction, there is one discrete element between the given opening and an adjacent opening aligned in the second direction. Each portion of the thermoplastic backing around the given opening is plastically deformed in its lengthwise direction. A method of making a laminate is also disclosed. The method includes stretching a thermoplastic backing having a plurality of discrete elements in the first direction and laminating the backing to an extensible carrier. Subsequently stretching the laminate in a second direction forms a tear in the thermoplastic backing between two adjacent of the discrete elements.

BACKGROUND

Articles with one or more structured surfaces are useful in a variety ofapplications (e.g., abrasive discs, assembly of automobile parts, anddisposable absorbent articles). The articles may be provided as filmsthat exhibit, for example, increased surface area, mechanical fasteningstructures, or optical properties.

Mechanical fasteners, which are also called hook and loop fasteners,typically include a plurality of closely spaced upstanding projectionswith loop-engaging heads useful as hook members, and loop memberstypically include a plurality of woven, nonwoven, or knitted loops.Mechanical fasteners are useful for providing releasable attachment innumerous applications. For example, mechanical fasteners are widely usedin wearable disposable absorbent articles to fasten such articles aroundthe body of a person. In typical configurations, a hook strip or patchon a fastening tab attached to the rear waist portion of a diaper orincontinence garment, for example, can fasten to a landing zone of loopmaterial on the front waist region, or the hook strip or patch canfasten to the backsheet (e.g., nonwoven backsheet) of the diaper orincontinence garment in the front waist region. Mechanical fasteners arealso useful for disposable articles such as sanitary napkins. A sanitarynapkin typically includes a back sheet that is intended to be placedadjacent to the wearer's undergarment. The back sheet may comprise hookfastener elements to securely attach the sanitary napkin to theundergarment, which mechanically engages with the hook fastenerelements.

Some mechanical fasteners have been made with openings in the backingfrom which male fastening elements project. See, e.g., U.S. Pat. No.4,001,366 (Brumlik) and U.S. Pat. No. 7,407,496 (Peterson), U.S. Pat.Appl. Pub. No. 2012/0204383 (Wood et al.), and Int. Pat. Appl. Pub. Nos.WO 2005/122818 (Ausen et al.) and WO 1994/02091 (Hamilton).

SUMMARY

The present disclosure provides a laminate of a reticulated film and amethod of making a laminate. A reticulated film can be made on anextensible laminate simply by stretching a thermoplastic backing in afirst direction, laminating the thermoplastic backing to an extensiblecarrier, and then stretching the laminate in a second directionperpendicular to the first direction. No slitting or aperturing of thefilm is needed before stretching. The method of making the laminate ofthe reticulated film takes advantage of the lower tear strengthassociated with stretch-induced molecular orientation of a film.

In one aspect, the present disclosure provides a laminate of an at leastpartially reticulated thermoplastic film joined to an extensiblecarrier. The reticulated thermoplastic film has a thermoplastic backingwith first and second major surfaces, a plurality of openings in thethermoplastic backing, and a plurality of discrete elements protrudingfrom the first major surface of the thermoplastic backing. There are twodiscrete elements, aligned in a first direction, abutting opposite endsof any given opening. In a second direction perpendicular to the firstdirection, there is one discrete element between the given opening andan adjacent opening aligned in the second direction. Each portion of thethermoplastic backing around the given opening is plastically deformedin its lengthwise direction.

In another aspect, the present disclosure provides a method of making alaminate. The method includes providing a thermoplastic backing havingfirst and second major surfaces and a plurality of discrete elementsprotruding from the first major surface of the thermoplastic backing. Atleast some of the discrete elements are aligned in a row in a firstdirection. The method further includes stretching the thermoplasticbacking in the first direction to plastically deform the thermoplasticbacking and separate the at least some of the discrete elements alignedin the row in the first direction. The thermoplastic backing remainsintact between the plurality of discrete elements after stretching it inthe first direction. The method further includes laminating thethermoplastic backing to an extensible carrier to provide a laminate.The extensible carrier is extensible in at least a second directionperpendicular to the first direction. The method further includesstretching the laminate in a second direction perpendicular to the firstdirection. Stretching the laminate in the second direction forms a tearin the thermoplastic backing between two adjacent of the discreteelements aligned in the row in the first direction, and the tear isinterrupted by the two adjacent of the discrete elements.

The method disclosed herein may be useful, in some embodiments, formaking a reticulated mechanical fastening laminate web, strip, or patchthat has a unique and attractive appearance. The method according to thepresent disclosure allows openings to be provided in the mechanicalfastener without wasteful material loss. The openings can providebreathability and flexibility to the mechanical fastener, which mayenhance the comfort of the wearer, for example, of an absorbent articlecomprising the mechanical fastener made by the method disclosed herein.The mechanical fastener also is typically able to cover a relativelylarge area with a relatively small amount of material, which may lowerits cost. Also, because of the large area that may be covered by themechanical fastener in an absorbent article, the mechanical fastener mayprovide performance enhancement, for example, by resisting shiftingforces such as torsional or rotational forces caused by movement of thewearer of the absorbent article. For example, in use, fitting anabsorbent article such as a diaper about the wearer usually requires thefront and back waist portions of the diaper to overlap each other. Asthe diaper is worn the movements of the wearer tend to cause theoverlapping front and back waist portions to shift position relative toeach other. Unless such shifting is limited, the fit and containmentcharacteristics of the diaper may be degraded as the diaper is worn. Themechanical fastener made according to the present disclosure may provideimproved fit and closure stability by resisting such shifting because ofits relatively larger area and flexibility.

In this application, terms such as “a”, “an” and “the” are not intendedto refer to only a singular entity, but include the general class ofwhich a specific example may be used for illustration. The terms “a”,“an”, and “the” are used interchangeably with the term “at least one”.The phrases “at least one of” and “comprises at least one of” followedby a list refers to any one of the items in the list and any combinationof two or more items in the list. All numerical ranges are inclusive oftheir endpoints and non-integral values between the endpoints unlessotherwise stated.

The terms “first” and “second” are used in this disclosure. It will beunderstood that, unless otherwise noted, those terms are used in theirrelative sense only. The designation of “first” and “second” may beapplied to the major surfaces of the thermoplastic backing merely as amatter of convenience in the description of one or more of theembodiments.

By using words of orientation such as “overlying” and “underlying” andversions thereof for the location of various elements in the disclosedlaminates, we refer to the relative position of an element with respectto a horizontally-disposed laminate with an upwardly-facing reticulatedfilm. It is not intended that the laminates should have any particularorientation in space during or after manufacture.

The terms “multiple” and “a plurality” refer to more than one.

The term “opening” should be understood to be a void space that issurrounded by the thermoplastic backing. The opening may or may notenclose fibrils of the thermoplastic backing, which typically have awidth that is less than 10 percent or less than 5 percent of the widthof each portion of the thermoplastic backing around the opening.

In some embodiments, the reticulated film according to the presentdisclosure is a continuous or running web, sometimes having anindefinite length. A web can typically be handled in a roll-to-rollprocess. In some embodiments, the method according to the presentdisclosure is carried out on a continuous web. The term “machinedirection” (MD) as used herein denotes the direction of a running web ofmaterial during a manufacturing process. When a strip is cut from acontinuous web, the machine direction corresponds to the length “L” ofthe strip. The terms “machine direction” and “longitudinal direction”may be used interchangeably. The term “cross-machine direction” (CD) asused herein denotes the direction which is essentially perpendicular tothe machine direction. When a strip is cut from a continuous web, thecross-machine direction corresponds to the width “W” of the strip. Insome embodiments of the method disclosed herein, the first direction isthe machine direction, and the second direction is the cross-machinedirection, but this is not a requirement.

The term “extensible” refers to a material that can be extended orelongated in the direction of an applied stretching force withoutdestroying the structure of the material or material fibers. An elasticmaterial is an extensible material that has recovery properties. In someembodiments, an extensible material may be stretched to a length that isat least about 5, 10, 15, 20, 25, or 50 percent greater than its relaxedlength without destroying the structure of the material or materialfibers.

The term “elastic” refers to any material (such as a film that is 0.002mm to 0.5 mm thick) that exhibits recovery from stretching ordeformation. In some embodiments, a material may be considered to beelastic if, upon application of a stretching force, it can be stretchedto a length that is at least about 25 (in some embodiments, 50) percentlarger than its initial length and can recover at least 40, 50, 60, 70,80, or 90 percent of its elongation upon release of the stretchingforce.

The term “non-elastic” refers to any material (such as a film that is0.002 mm to 0.5 mm thick) that does not exhibit recovery from stretchingor deformation to a large extent. For example, a non-elastic materialthat is stretched to a length that is at least about 50 percent greaterthan its initial length will recover less than about 40, 25, 20, or 10percent of its elongation upon release of its stretching force. In someembodiments, a non-elastic material may be considered to be a flexibleplastic that is capable of undergoing permanent plastic deformation ifit is stretched past its reversible stretching region.

The above summary of the present disclosure is not intended to describeeach disclosed embodiment or every implementation of the presentdisclosure. The description that follows more particularly exemplifiesillustrative embodiments. It is to be understood, therefore, that thedrawings and following description are for illustration purposes onlyand should not be read in a manner that would unduly limit the scope ofthis disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various embodiments of the disclosurein connection with the accompanying drawings, in which:

FIG. 1A is a top view of one embodiment of a film useful for the methodof making a laminate according to the present disclosure;

FIG. 1B is a top view of the film shown in FIG. 1A after it has beenstretched in a first direction;

FIG. 1C is a perspective view of a film shown in FIG. 1B laminated to anextensible carrier;

FIG. 1D is a top view of an embodiment of a laminate according to thepresent disclosure, which, according to some embodiments of the methodaccording to the present disclosure, is prepared by stretching the filmshown in FIG. 1B in a second direction perpendicular to the firstdirection;

FIG. 2 is a scanning electron micrograph showing a perspective view of aportion of a reticulated film similar to that shown in FIG. 1D;

FIG. 3A is a photograph taken with a polarization microscope equippedwith cross polars of a film such as that shown in FIG. 1B after it hasbeen stretched in a first direction;

FIG. 3B is a photograph taken with a polarization microscope equippedwith cross polars of the film shown in FIG. 3A after it has beenstretched in a second direction perpendicular to the first direction;

FIGS. 3C and 3D are micrographs showing optical retardance maps of twoportions of the thermoplastic backing between openings in a reticulatedfilm according to the present disclosure;

FIG. 4 is a top view of another embodiment of a laminate according tothe present disclosure;

FIG. 5 is a perspective view of yet another embodiment of a laminateaccording to the present disclosure;

FIG. 6A is a picture of an embodiment of the reticulated film accordingto the present disclosure in which the thermoplastic backing was notheated while stretching in the second direction;

FIG. 6B is a picture of an embodiment of the reticulated film accordingto the present disclosure in which the thermoplastic backing was heatedwhile stretching in the second direction;

FIG. 7A is a portion of an extension versus load graph observed forExample 1; and

FIG. 7B is a portion of an extension versus load graph observed for themethod of making a reticulated film, wherein the reticulated film is notjoined to a carrier.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the disclosure,one or more examples of which are illustrated in the drawings. Featuresillustrated or described as part of one embodiment can be used withother embodiments to yield still a third embodiment. It is intended thatthe present disclosure include these and other modifications andvariations.

FIG. 1A shows a top view of an embodiment of a thermoplastic backing 14with discrete elements 10 protruding from the first major surface of thebacking, which is the major surface visible in the drawing.

FIG. 1B illustrates the result of stretching the thermoplastic backing14 in the first direction 1D, which is a feature of the method accordingto the present disclosure. FIG. 1B illustrates that the discreteelements 10 are spaced further apart in first direction 1D afterstretching. Although not shown in the drawing, the thermoplastic backing14 becomes thinner, is plastically deformed, and has stretch-inducedmolecular orientation in the first direction 1D. However, thethermoplastic backing 14 remains intact between the discrete elements 10after stretching. In other words, the thermoplastic backing 14 does nothave a plurality of any of cuts, slits, tears, or apertures afterstretching in the first direction; instead the backing remains acontinuous film. During the stretching in the first direction, thediscrete elements 10 formed in the thermoplastic backing 14 resiststretching. At their bases, the areas of the discrete elements 10 behaveas thicker portions of film and do not stretch to the same extent as thethermoplastic backing 14 on either side. To compensate for thisresistance to stretching of the bases, at least a portion of the area 20of the thermoplastic backing between the discrete elements 10 isbelieved to stretch to a greater extent than the thermoplastic backing14 on either side. The regions of the thermoplastic backing 14 with thehighest stretch-induced molecular orientation in the first direction 1Dare therefore found within areas 20 between the discrete elements 10.

FIG. 1C is a perspective view of a laminate of the thermoplastic backing14 with discrete elements 10 shown in FIG. 1B laminated to an extensiblecarrier 30. In some embodiments, at least some of the discrete elementscomprise one upstanding post. In some embodiments, at least some of thediscrete elements 10 are upstanding posts on the thermoplastic backing14, which typically have proximal ends 10 a and distal ends 10 b, withthe proximal end including the base that is attached to thethermoplastic backing 14, and the distal end extending away from thethermoplastic backing. The extensible carrier 30 is extensible at leastin the second direction 2D and is generally selected such that it has alower yield point than that of the thermoplastic backing 14 withdiscrete elements 10.

FIG. 1D illustrates the result of stretching the laminate 5 in thesecond direction 2D, which is a feature of the method according to thepresent disclosure. Second direction 2D is perpendicular to firstdirection 1D. Since the areas 20 shown in FIG. 1B have the higheststretch-induced molecular orientation in the thermoplastic backing 14 inthe first direction, they have the lowest tear resistance. Stretchingthe laminate 5 in the second direction 2D causes the thermoplasticbacking 14 to tear in areas 20 to provide the openings 22 in thethermoplastic backing 14 as shown in FIG. 1D. The tears in areas 20 areinterrupted by the discrete elements 10 on either end of areas 20. Adiscrete element according to some embodiments of the method accordingto the present disclosure that interrupts tear propagation is shown inthe scanning electron micrograph of FIG. 2 although this micrograph isof a backing that was not stretched while laminated to an extensiblecarrier. In some embodiments, including the embodiment shown in FIG. 2,the discrete elements protrude only from the first major surface of thethermoplastic backing. It should be understood that the thermoplasticbacking 14 shown in FIG. 1C is not slit or apertured. Instead, openings22 are formed in the thermoplastic backing 14 simply by stretching thethermoplastic backing 14 in the first direction 1D and then stretchingthe laminate shown in FIG. 1C in the second direction 2D.

Although stretching the film shown in FIG. 1B in the second direction 2Dcan be carried out without laminating it to an extensible carrier,stretching the laminate shown in FIG. 1C in the second direction 2D canbe carried out more quickly. When stretching the film shown in FIG. 1Bin the second direction, each tear induces a weak point in thethermoplastic backing, and the stretching forces become exerted only onthe portions of the thermoplastic backing between the openings, withhigh stress exerted on the thermoplastic backing at the positions of thediscrete elements. In the laminate 5 shown in FIG. 1D, the stretchingforces are exerted mainly on the extensible carrier 30. As a result,stretching a laminate in the second direction 2D can be carried out atleast ten times faster than stretching the thermoplastic film itself.

FIG. 1D also illustrates an embodiment of a laminate 5 according to thepresent disclosure. In the embodiment illustrated in FIG. 1D, thethermoplastic backing 14 has a staggered array of discrete elements 10protruding from its first major surface when viewed in either the firstdirection 1D or the second direction 2D. A staggered array may appear tobe a square array depending on the angle of viewing; therefore, theangle of viewing is specified. In some embodiments, a staggered array isan array that appears staggered when viewed from the first direction.Referring again to the embodiment of the method illustrated in FIGS.1A-1D, discrete elements 10 are aligned in rows 16 in the firstdirection 1D but are staggered in the second direction 2D.

In the reticulated film 1 shown in FIG. 1D, for any given single opening22 in the reticulated film, there are four discrete elements 10 aroundthe single opening 22. Two discrete elements 10 abut the opening onopposite ends, which are the discrete elements that serve to interruptthe tears formed in the thermoplastic backing upon stretching in thesecond direction 2D in the method disclosed herein. The remaining twodiscrete elements of the four discrete elements around the opening havea portion of thermoplastic backing 14 between them and the opening 22.There is one discrete element between the given opening and an adjacentopening aligned in the second direction. In some embodiments, when twoopenings are said to be aligned, they are aligned along an axis ofsymmetry. No portion of the thermoplastic backing 14 connects either ofthe two pairs of opposing discrete elements 10 in the group of fourdiscrete elements.

Furthermore, between any two adjacent openings, there is generally up toone discrete element protruding from the thermoplastic backing. That is,there may be zero or one discrete element between any two adjacentopenings. For the purposes of the present disclosure, to determinewhether a discrete element is between two adjacent openings, thediscrete element must be located somewhere on the portion of thethermoplastic backing that separates the two adjacent openings. Whenviewed down rows 16, the reticulated film 1 clearly has one discreteelement 10 between any two adjacent openings 22. Also, when viewed indirection 2D, which is perpendicular to rows 16, the reticulated film 1clearly has one discrete element 10 between any two adjacent openings22. Thus, when viewed along an axis of symmetry along which a pluralityof openings is aligned, there is one discrete element 10 between any twoadjacent openings. However, when viewed at a 45 degree angle to rows 16,the reticulated film 1 may be considered to have no discrete element 10between any two adjacent openings 22 since the discrete elements 10 arenot located in the portion of the thermoplastic backing 14 thatseparates the two openings 22. In some embodiments, including theembodiment shown in FIG. 1C, there appears to be exactly one discreteelement 10 at every intersection in the reticulated film 1. An openingand the associated portions of thermoplastic backing that surround itcan be referred to as the unit cell of the reticulated film. In someembodiments, including the embodiment shown in FIG. 1D, the unit cellhas four sides and four angles, and there appears to be exactly onediscrete element 10 associated with each angle in the unit cell.

In laminates made according to the method disclosed herein, thereticulated film typically has other unique features. Because thethermoplastic backing is first stretched in the first direction 1D, eachportion of the thermoplastic backing 14 defined by a width dimension “w”and a length dimension “l” is plastically deformed in its lengthwisedirection. As used herein the terms “length” or “lengthwise” typicallyrefer to the longest dimension of the portion of the thermoplasticbacking between openings although the original density and dimensions ofthe discrete elements and the degree of stretching in the firstdirection can alter the dimensions of the thermoplastic backingportions. The lengthwise direction may also be considered the firstdirection when the openings are retracted or closed such as when theextensible carrier is elastic and in its retracted state or when thereticulated film is removed from the non-elastic extensible carrier andtension is applied in the first direction to at least partially closethe openings. As used herein the term “width” typically refers to theshortest dimension in the plane of the thermoplastic backing of theportion of the backing between openings. The width dimension may also beconsidered parallel to the second direction when the openings areretracted or closed. Each portion of the thermoplastic backing typicallyhas a greater stretch-induced molecular orientation in the lengthdimension than in the width dimension. There may be no stretch-inducedmolecular orientation in the width dimension “w” because thethermoplastic backing tears instead of stretching when extended in thesecond direction, or there may be some localized stretch-inducedmolecular orientation in the width dimension at connection points. Also,the thickness of the thermoplastic backing 14 can be substantiallyuniform in the reticulated film 1. The thickness of the thermoplasticbacking 14 after stretching in the first direction 1D as shown in FIG.1B is the same as the thickness of the thermoplastic backing 14 afterstretching in the second direction 2D as shown in FIG. 1D again becausethe thermoplastic backing tears instead of stretching when extended inthe second direction.

Stretch-induced molecular orientation in the reticulated film accordingto the present disclosure can be determined by standard spectrographicanalysis of the birefringent properties of the thermoplastic backing inthe reticulated film. Each portion of the thermoplastic backing betweenthe openings in the reticulated film may also be understood to bebirefringent, which means that the polymer in the thermoplastic backinghas different effective indexes of refraction in different directions.As described above in connection with FIG. 1B, stretch-induced molecularorientation in the thermoplastic backing 14 is believed to be highestwithin areas 20. A photograph taken with a polarization microscopeequipped with cross polars, shown in FIG. 3A, illustrates this point. Inthe gray scale image shown in FIG. 3A, the darker, triangular area aboveand below the round upstanding elements reveals that the highestbirefringence in the film is between the discrete elements. FIG. 3B is aphotograph taken of the film shown in FIG. 3A after is has beenstretched in the second direction. FIG. 3B illustrates that thebirefringence that results from the stretch-induced molecularorientation in the thermoplastic backing of the reticulated film ishighest where it abuts an opening. The lighter color on the edges ofeach portion of the thermoplastic backing shown in FIG. 3B revealshigher birefringence at or near the edges than in the center portion ofthe thermoplastic backing. Referring again to FIG. 1D, birefringencefrom stretch-induced molecular orientation is typically higher at theposition 24 a at the edge of an opening than in a portion of thethermoplastic backing that does not abut an opening, for example, at 24b or at a mid-point of the portion of the thermoplastic backing.Although not visible in the gray scale image of FIG. 3B, the highestbirefringence is located in the thermoplastic backing on the edge of theopening near the location of the discrete element.

The higher stretch-induced molecular orientation at a location at theedge of a given opening would not be observed in a backing that is slit,apertured, or molded to have openings. In cases where stretching followsslitting, aperturing, or molding an opening, for example, stretchingwould not preferentially occur at the slit, aperture, or opening toprovide increased birefringence at that location. At a slit, aperture,or molded opening, there is an interruption in material and therefore nomaterial to transmit the stretching force. Therefore, there is no reasonto believe that a higher level of stretch-induced molecular orientationwould be observed at the edge of an opening than toward the center of aportion of a thermoplastic backing between openings.

In many embodiments, including the embodiment that is shown in FIG. 3B,at least one (in some embodiments, each) portion of the thermoplasticbacking that surrounds a given opening has a similar profile across itswidth of higher birefringence toward the opening and lower birefringencetoward the center of each portion of the thermoplastic backing.

To determine whether a reticulated film has generally higherstretch-induced molecular orientation in a portion of the thermoplasticbacking near the edge of a given opening than in the center of theportion and/or to determine whether each portion of the thermoplasticbacking that surrounds a given opening has a similar profile across itswidth of higher birefringence toward the opening, a polarizationmicroscope such as a “LEICA DM2700P”, obtained from Microsystems GmbH,Wetzlar, Germany, equipped with cross polars is used in transmissionmode. The polarizer and analyzer are placed at 90 degrees to each othersuch that the field of view is dark. The sample is placed between thepolarizer and analyzer, and the image is recorded using an imagecapturing device.

Also, higher birefringence at the edges of each portion of thethermoplastic backing in reticulated films disclosed herein is shown bycross sectioning the portions of the thermoplastic backing and measuringbirefringence. Referring again to FIG. 1D, a unit cell in reticulatedfilm 1 was cut in 2D in two places “a” and “b” to cut through eachportion of the thermoplastic backing in the cell. A cross-section ofeach cut portion was photographed to show the optical retardance map ofeach sample. Two of the photographs are shown in FIGS. 3C and 3D. Areasof lighter color indicate areas of higher birefringence. In thephotographs shown in FIGS. 3C and 3D, the highest birefringence isobserved at one edge of each cross-section. The birefringence in thesesamples was measured with a retardance imaging system available fromLot-Oriel GmbH & Co., Darmstadt, Germany, under the trade designation“LC-PolScope” on a microscope available from Leica Microsystems GmbH,under the trade designation “DMRXE” and a digital CCD color cameraavailable from QImaging, Surrey, BC, Canada, under the trade designation“RETIGA EXi FAST 1394”. The microscope was equipped with a 546.5 nminterference filter obtained from Cambridge Research & Instrumentation,Inc., Hopkinton, Mass., and a 10×/0.25 objective.

In some embodiments of the laminate according to the present disclosure,the carrier also has stretch induced molecular orientation if it isplastically deformed upon stretching in the second direction 2D. Thecarrier may have higher stretch-induced molecular orientation in thesecond direction 2D than in the first direction 1D. Stretch-inducedmolecular orientation in the carrier can also be determined by standardspectrographic analysis of its birefringent properties using either ofthe techniques described above.

For some embodiments of the reticulated film disclosed herein,particularly embodiments in which the extensible carrier is non-elasticor when the extensible carrier is elastic and stretched, the openingsformed in the thermoplastic backing are in the form of a repeatingpattern of quadrilaterals. The quadrilaterals generally have two axes ofsymmetry, one in 1D and one in 2D. In some embodiments, the openings arein the shape of rhombuses. Again, no portion of the thermoplasticbacking bridges between opposing angles of the quadrilaterals.Extensible carriers that are elastic may have retraction force thatcloses the openings once they are made. In these embodiments, when thestretching force is released, and the elastic is in its relaxed state,the openings may be very narrow and appear as slits. There may be morethan one repeating pattern of quadrilateral-shaped openings or slits,for example, if the discrete elements are not evenly spaced on thethermoplastic backing. There may be zones in the thermoplastic backinghaving different spacings of the discrete elements, giving rise todifferent sizes of the discrete openings. For discrete elements that areevenly spaced, the spacing (e.g., distance in the CD) between thediscrete openings may differ by up to 10, 5, 2.5, or 1 percent.

In the laminate according to the present disclosure, the reticulatedfilm may be partially reticulated, for example, in embodiments in whichonly a portion of the extensible carrier is stretched.

The thermoplastic backing in the reticulated film 1 in the laminateaccording to the present disclosure and in its precursors in the methodaccording to the present disclosure is substantially planar. Asubstantially “planar” reticulated film refers to the portions ofthermoplastic backing or strands occupying substantially the same planewhen placed on a flat surface. The term “substantially” in this regardcan mean that a portion of the thermoplastic backing may be out of planeby up to 15, 10, or 5 degrees. A thermoplastic backing that issubstantially planar is not corrugated and not profile-extruded to havemultiple peaks and valleys. The various portions of the thermoplasticbacking also do not cross over each other, for example, at intersectionsof the reticulated film in a “substantially planar” film.

Although FIGS. 1A through 1D illustrate an embodiment of the methodaccording to the present disclosure in which the discrete elements 10are aligned in rows 16 in the first direction 1D, which is the directionof the first stretch, other relationships between the discrete elementsand the first direction may be useful. For example, for a thermoplasticbacking having a square array of discrete elements, the first directionmay be at a 45 degree angle to a given row of discrete elements. Asecond stretch in a second direction perpendicular to the firstdirection after joining the thermoplastic backing to a carrier willprovide openings in the thermoplastic backing.

FIG. 4 illustrates another embodiment of the laminate according to thepresent disclosure. The reticulated film 101 laminated to carrier 130 inlaminate 105 has a staggered array of discrete elements 110 protrudingfrom the first major surface of the thermoplastic backing. In theillustrated embodiment, the discrete elements 110 comprise multipleupstanding posts on a surface protrusion. The upstanding posts each haveproximal ends and distal ends, with the proximal end including the basethat is attached to the surface protrusion, and the distal end extendingaway from the thermoplastic backing. As in the reticulated film shown inthe embodiment of FIG. 1D, between any two adjacent openings 122, thereis up to one discrete element 110 protruding from the thermoplasticbacking; there is exactly one discrete element 110 at every intersectionin the reticulated film 101. Also, in the illustrated embodiment, forany given single opening 122 in the reticulated film 101, there are fourdiscrete elements 110 around the single opening 122, with two discreteelements 110 abutting the opening 122 on opposite ends and the remainingtwo discrete elements of the four discrete elements around the openinghaving a portion of thermoplastic backing 114 between them and theopening 122. There is one discrete element between the given opening 122and an adjacent opening aligned in the second direction. Thestretch-induced molecular orientation in the thermoplastic backing 114of reticulated film 101 is typically highest where it abuts an opening,for example, at 124 a. In other words, the stretch-induced molecularorientation is typically higher at the position 124 a than in a portionof the thermoplastic backing that does not abut an opening, for example,at 124 b. Moreover, each portion of the thermoplastic backing thatsurrounds a given opening has a similar profile across its width ofhigher birefringence toward the opening and lower birefringence towardthe center.

Various features of thermoplastic backing having discrete elementsprotruding therefrom (such as that shown in FIG. 1A) can influence themethod according to the present disclosure and also can affect theappearance and properties of the resultant laminate. For example, thethickness of the thermoplastic backing is related to the degree ofstretching (that is, draw ratio) in the first direction that is requiredto cause area 20 (shown in FIG. 1B) to tear upon stretching in thesecond direction. The term “draw ratio” refers to ratio of a lineardimension of a given portion of the thermoplastic backing afterstretching to the linear dimension of the same portion beforestretching. The method according to the present disclosure can be usefulwith thermoplastic backings having a variety of thicknesses. In someembodiments, the thickness of the thermoplastic backing suitable for themethod disclosed herein may be up to about 400 micrometers, 300micrometers, or 250 micrometers and at least about 30 micrometers or 50micrometers before stretching in the first direction, depending on thedesired reticulated film in the laminate. This thickness does notinclude the height of the discrete elements protruding from the firstmajor surface of the thermoplastic backing. In some embodiments, thethickness of the thermoplastic backing is in a range from 30 to about225 micrometers, from about 50 to about 200 micrometers, or from about50 to about 150 micrometers before stretching in the first direction.Thin films will require a lower draw ratio in the first direction thanthicker films to provide the desired amount of stretch-induced molecularorientation in area 20. The selection of material for the thermoplasticbacking also impacts the draw ratio. For a polypropylene or polyethylenebacking, the draw ratio in the first direction sufficient to provide thedesired amount of stretch-induced molecular orientation in area 20 canbe 1.25, 1.5, 2.0, 2.25, 2.5, 2.75, or 3, depending on the thickness ofthe backing and the temperature of the backing when it is stretched. Forexample, the draw ratio in the first direction for a backing 70micrometers thick may be about 2, the draw ratio in the first directionfor a backing 100 micrometers thick may be in a range from about 2.2 to2.5, and the draw ratio in the first direction for a backing 130micrometers thick may be in a range from about 2.5 to 2.75 whenstretching any of these backings is carried out at a temperature in arange from 85° C. to 130° C., for example. The maximum draw ratio islimited by the tensile strength of the selected material. Draw ratios ofup to 5, 7.5, or 10 may be useful, depending on material selection andthe temperature of the thermoplastic backing when it is stretched.

The width of the discrete element 10 or 110 at its base (that is, thepoint where it begins to protrude from the thermoplastic backing) alsocan influence the method according to the present disclosure. The term“width dimension” should be understood to include the diameter of adiscrete element 10 with a circular cross-section. The discrete element10 may have more than one width dimension (e.g., in a rectangular orelliptical cross-section shaped post). Furthermore, the discrete element10 may taper, for example, from the proximal end at the base toward thedistal end, as shown in FIG. 2. In these cases, the width of thediscrete element is considered to be its greatest width at its base. Thewidth of discrete elements affects their resistance to stretching in thefirst direction and therefore affects the amount of increased stretchingin area 20 of the thermoplastic backing between the discrete elements 10relative to the thermoplastic backing 14 on either side. In someembodiments, the discrete element has a width that is at least as big asthe thickness of the film as described in any of the embodiments listedabove. The discrete elements 10 may have a cross-section with a maximumwidth dimension “w” of at least 30 micrometers, 50 micrometers, 70micrometers, 100 micrometers, or 125 micrometers. The width of thediscrete element 10 may be up to 1 millimeter in some embodiments. Insome embodiments, the discrete elements 10 have a cross-section with awidth dimension “w” in a range from 70 micrometers to 500 micrometers or100 micrometers to 400 micrometers.

The draw ratio and the width of the discrete elements 10 or 110 at thebase also influence the appearance and/or properties of the resultantreticulated film in the laminate, for example, width of the portions (orstrands) of the thermoplastic backing 14 or 114 and basis weight of thereticulated film. For a given film, a higher draw ratio provides lowerstrand widths and lower basis weight nets. Wider discrete elements alsoprovide lower strand widths.

The density of the discrete elements 10 or 110 on the thermoplasticbacking 14 or 114 also influences the appearance and/or properties ofthe reticulated film in the laminate according to the presentdisclosure. A variety of densities of the discrete elements may beuseful, and for a given film, a higher density of discrete elementsprovides lower strand widths in the reticulated film. In someembodiments, the density of discrete elements on the thermoplasticbacking is in a range from 20 per cm² to 1000 per cm² (in someembodiments, in a range from 20 per cm² to 500 per cm², 50 per cm² to500 per cm², 60 per cm² to 400 per cm², 75 per cm² to 350 per cm², 100per cm² to 300 per cm², or 200 per cm² to 1000 per cm²).

The discrete element protruding from the thermoplastic backing in themethod and laminate according to the present disclosure may have avariety of heights. The discrete element useful for providing resistanceto stretching in the method according to the present disclosure may havea height above the thermoplastic backing of at least 30 micrometers. Insome embodiments, the discrete elements have a maximum height (above thebacking) of up to 3 mm, 1.5 mm, 1 mm, or 0.5 mm and, in some embodimentsa minimum height of at least 50 micrometers, 100 micrometers, or 200micrometers. In some embodiments, the discrete elements have an aspectratio (that is, a ratio of height to width at the widest point) of atleast about 0.25:1, 1:1, 2:1, 3:1, or 4:1.

It should be understood from the present disclosure that the discreteelements refer to elements that are separate and distinct from eachother. They are not part of a continuous ridge or rib in thermoplasticbacking, either before or after stretching. Furthermore, the discreteelements are separate and distinct from the thermoplastic backing. Insome embodiments, the thermoplastic backing, excluding the discreteelements, is substantially uniform in thickness. For a thermoplasticbacking that is substantially uniform in thickness, a difference inthickness between any two points in the thermoplastic backing may be up5, 2.5, or 1 percent.

The thermoplastic backing useful for practicing the method disclosedherein and useful for the resulting reticulated film in the laminate maybe made from a variety of suitable materials. Suitable thermoplasticmaterials include polyolefin homopolymers such as polyethylene andpolypropylene, copolymers of ethylene, propylene and/or butylene;copolymers containing ethylene such as ethylene vinyl acetate andethylene acrylic acid; polyesters such as poly(ethylene terephthalate),polyethylene butyrate and polyethylene napthalate; polyamides such aspoly(hexamethylene adipamide); polyurethanes; polycarbonates; poly(vinylalcohol); ketones such as polyetheretherketone; polyphenylene sulfide;and mixtures thereof. In some embodiments, the thermoplastic is apolyolefin (e.g., polyethylene, polypropylene, polybutylene, ethylenecopolymers, propylene copolymers, butylene copolymers, and copolymersand blends of these materials). For any of the embodiments in which thethermoplastic backing includes polypropylene, the polypropylene mayinclude alpha and/or beta phase polypropylene. In some cases, athermoplastic backing such as that shown in FIGS. 1A and 1B thatincludes beta-phase polypropylene before stretching in the firstdirection 1D may include alpha-phase polypropylene after stretching.Since the reticulated film in the laminate according to the presentdisclosure and/or made according to the present disclosure has athermoplastic backing that is plastically deformed, it should beunderstood that the thermoplastic backing is generally non-elastic.

In some embodiments, the thermoplastic backing 14 or 114 with discreteelements 10 or 110 can be made from a multilayer or multi-component meltstream of thermoplastic materials. This can result in discrete elementsformed at least partially from a different thermoplastic material thanthe one predominately forming the backing. Various configurations ofupstanding posts made from a multilayer melt stream are shown in U.S.Pat. No. 6,106,922 (Cejka et al.), for example. A multilayer ormulti-component melt stream can be formed by any conventional method. Amultilayer melt stream can be formed by a multilayer feedblock, such asthat shown in U.S. Pat. No. 4,839,131 (Cloeren). A multicomponent meltstream having domains or regions with different components could also beused. Useful multicomponent melt streams could be formed by use ofinclusion co-extrusion die or other known methods (e.g., that shown inU.S. Pat. No. 6,767,492 (Norquist et al.).

For the method and laminate according to the present disclosure, thethermoplastic backing and the discrete elements are integral (that is,generally formed at the same time as a unit, unitary). Discrete elementssuch as upstanding posts on a backing can be made, for example, byfeeding a thermoplastic material onto a continuously moving mold surfacewith cavities having the inverse shape of the discrete elements. Thethermoplastic material can be passed between a nip formed by two rollsor a nip between a die face and roll surface, with at least one of therolls having the cavities. Pressure provided by the nip forces the resininto the cavities. In some embodiments, a vacuum can be used to evacuatethe cavities for easier filling of the cavities. The nip has a largeenough gap such that a coherent thermoplastic backing is formed over thecavities. The mold surface and cavities can optionally be air or watercooled before stripping the integrally formed backing and upstandingposts from the mold surface such as by a stripper roll.

Suitable mold surfaces for forming discrete elements that include oneupstanding post include tool rolls such as those formed from a series ofplates defining a plurality of cavities about its periphery includingthose described, for example, in U.S. Pat. No. 4,775,310 (Fischer).Cavities may be formed in the plates by drilling or photoresisttechnology, for example. Other suitable tool rolls may includewire-wrapped rolls, which are disclosed along with their method ofmanufacturing, for example, in U.S. Pat. No. 6,190,594 (Gorman et al.).Another example of a method for forming a thermoplastic backing withupstanding posts includes using a flexible mold belt defining an arrayof upstanding post-shaped cavities as described in U.S. Pat. No.7,214,334 (Jens et al.). Yet other useful methods for forming athermoplastic backing with upstanding posts can be found in U.S. Pat.No. 6,287,665 (Hammer), U.S. Pat. No. 7,198,743 (Tuma), and U.S. Pat.No. 6,627,133 (Tuma).

While in some embodiments, at least some of the discrete elements on thethermoplastic backing comprise one upstanding post, in otherembodiments, at least some of the discrete elements comprise multipleupstanding posts on a surface protrusion. In these embodiments, thediscrete elements can be made by a modification of the mold surfacedescribed above, in which the cavity includes a main cavity withmultiple smaller cavities within the main cavity.

In any of the mold surfaces mentioned above, the cavities and theresultant discrete elements may have a variety of cross-sectionalshapes. For example, the cross-sectional shape of the cavity anddiscrete element may be a polygon (e.g., square, rectangle, rhombus,hexagon, pentagon, or dodecagon), which may be a regular polygon or not,or the cross-sectional shape of the post may be curved (e.g., round orelliptical). The discrete element may taper from its base to its distaltip, for example, for easier removal from the cavity, but this is not arequirement. The cavity may have the inverse shape of a post having aloop-engaging head (e.g., a male fastening element) or may have theinverse shape of an upstanding post without loop-engaging heads that canbe formed into loop-engaging heads, if desired.

If upstanding posts formed upon exiting the cavities do not haveloop-engaging heads, loop-engaging heads could be subsequently formed bya capping method as described in U.S. Pat. No. 5,077,870 (Melbye etal.). Typically, the capping method includes deforming the tip portionsof the upstanding posts using heat and/or pressure. The heat andpressure, if both are used, could be applied sequentially orsimultaneously. The formation of male fastening elements can alsoinclude a step in which the shape of the cap is changed, for example, asdescribed in U.S. Pat. No. 6,132,660 (Kampfer). Such capping and capmodification steps can be carried out before or after stretching in thefirst direction or before or after stretching in the second direction inthe method of making a laminate disclosed herein.

For any of the embodiments described above in which the discreteelements are upstanding posts with loop-engaging overhangs, the term“loop-engaging” relates to the ability of a male fastening element to bemechanically attached to a loop material. Generally, male fasteningelements with loop-engaging heads have a head shape that is differentfrom the shape of the post. For example, the male fastening element maybe in the shape of a mushroom (e.g., with a circular or oval headenlarged with respect to the stem), a hook, a palm-tree, a nail, a T, ora J. In some embodiments, each discrete element includes an upstandingpost and a cap with loop engaging overhangs extending in multiple (i.e.,at least two) directions, in some embodiments, at least two orthogonaldirections. For example, the upstanding post may be in the shape of amushroom, a nail, a palm tree, or a T. In some embodiments, theupstanding posts are provided with a mushroom head (e.g., with an ovalor round cap distal from the thermoplastic backing). Theloop-engageability of male fastening elements may be determined anddefined by using standard woven, nonwoven, or knit materials. A regionof male fastening elements with loop-engaging heads generally willprovide, in combination with a loop material, at least one of a higherpeel strength, higher dynamic shear strength, or higher dynamic frictionthan a region of posts without loop-engaging heads. Male fasteningelements that have “loop-engaging overhangs” or “loop-engaging heads” donot include ribs that are precursors to fastening elements (e.g.,elongate ribs that are profile extruded and subsequently cut to formmale fastening elements upon stretching in the direction of the ribs).Such ribs would not be able to engage loops before they are cut andstretched. Such ribs would also not be considered upstanding posts ordiscrete elements. Typically, male fastening elements that haveloop-engaging heads have a maximum width dimension (in either dimensionnormal to the height) of up to about 1 (in some embodiments, 0.9, 0.8,0.7, 0.6, 0.5, or 0.45) millimeter. In some embodiments, the malefastening elements have a maximum height (above the backing) of up to 3mm, 1.5 mm, 1 mm, or 0.5 mm and, in some embodiments a minimum height ofat least 0.03 mm, 0.05 mm, 0.1 mm, or 0.2 mm. In some embodiments, theupstanding posts have aspect ratio (that is, a ratio of height to widthat the widest point) of at least about 0.25:1, 1:1, 2:1, 3:1, or 4:1.

Stretching in the first direction and subsequently the second directioncan be carried out using a variety of methods. Stretching in the machinedirection of a continuous web of indefinite length, monoaxial spreadingin the machine direction can be performed by propelling the web overrolls of increasing speed, with the downweb roll speed faster than theupweb roll speed. In some embodiments, the first direction is themachine direction. Stretching in a cross-machine direction can becarried out on a continuous web using, for example, diverging rails,diverging disks, a series of bowed rollers, or a crown surface. Methodsusing diverging disks or a crown surface described, for example, in U.S.Ser. No. 61/647,833 and U.S. Ser. No. 61/647,862, each filed on May 16,2012, may be useful for cross-direction stretching of the thermoplasticbacking in the method according to the present disclosure. In someembodiments, the first direction is either the machine direction orcross-direction, and the discrete elements are positioned in a staggeredarray when viewed in the machine direction or cross-direction,respectively.

In some embodiments, laminating the thermoplastic backing to anextensible carrier is carried out after stretching in the firstdirection. The thermoplastic backing may be joined to a carrier, forexample, by lamination (e.g., using thermal bonding or adhesives such aspressure sensitive adhesives), or other bonding methods (e.g.,ultrasonic bonding, compression bonding, or surface bonding). Thethermoplastic backing and the extensible carrier may be substantiallycontinuously bonded or intermittently bonded. “Substantiallycontinuously bonded” refers to being bonded without interruption inspace or pattern. Substantially continuously bonded laminates can beformed by passing the thermoplastic backing and the extensible carrierbetween a heated smooth surfaced roll nip if at least one of them isthermally bondable or applying a substantially continuous adhesivecoating or spray to one of the thermoplastic backing or extensiblecarrier before bringing it in contact with the other of thethermoplastic backing or extensible carrier. “Intermittently bonded” canmean not continuously bonded and refers to the thermoplastic backing andextensible carrier being bonded to one another at discrete spaced apartpoints or being substantially unbonded to one another in discrete,spaced apart areas. Intermittently bonded laminates can be formed, forexample, by ultrasonic point bonding, by passing the thermoplasticbacking and the extensible carrier through a heated patterned embossingroll nip if at least one of them is thermally bondable, or by applyingdiscrete, spaced apart areas of adhesive to one of the thermoplasticbacking or extensible carrier before bringing it into contact with theother of the thermoplastic backing or extensible carrier. Anintermittently bonded laminate can also be made by feeding an adhesivelycoated apertured ply or scrim between the thermoplastic backing and theextensible carrier.

In some embodiments, the thermoplastic backing of the reticulated filmdisclosed herein can be joined to a fibrous carrier using surfacebonding or loft-retaining bonding techniques. The term “surface-bonded”when referring to the bonding of fibrous materials means that parts offiber surfaces of at least portions of fibers are melt-bonded to thesecond surface of the backing, in such a manner as to substantiallypreserve the original (pre-bonded) shape of the second surface of thebacking, and to substantially preserve at least some portions of thesecond surface of the backing in an exposed condition, in thesurface-bonded area. Quantitatively, surface-bonded fibers may bedistinguished from embedded fibers in that at least about 65% of thesurface area of the surface-bonded fiber is visible above the secondsurface of the backing in the bonded portion of the fiber. Inspectionfrom more than one angle may be necessary to visualize the entirety ofthe surface area of the fiber. The term “loft-retaining bond” whenreferring to the bonding of fibrous materials means a bonded fibrousmaterial comprises a loft that is at least 80% of the loft exhibited bythe material prior to, or in the absence of, the bonding process. Theloft of a fibrous material as used herein is the ratio of the totalvolume occupied by the web (including fibers as well as interstitialspaces of the material that are not occupied by fibers) to the volumeoccupied by the material of the fibers alone. If only a portion of afibrous web has the second surface of the thermoplastic backing bondedthereto, the retained loft can be easily ascertained by comparing theloft of the fibrous web in the bonded area to that of the web in anunbonded area. It may be convenient in some circumstances to compare theloft of the bonded web to that of a sample of the same web before beingbonded, for example, if the entirety of fibrous web has the secondsurface of the thermoplastic backing bonded thereto. In some of theseembodiments, the joining comprises impinging heated gaseous fluid (e.g.,ambient air, dehumidified air, nitrogen, an inert gas, or other gasmixture) onto a first surface of the fibrous web carrier while it ismoving; impinging heated fluid onto the second surface of thethermoplastic backing while the continuous web is moving, wherein thesecond surface is opposite the discrete elements on the thermoplasticbacking; and contacting the first surface of the fibrous web with thesecond surface of the thermoplastic backing so that the first surface ofthe fibrous web is melt-bonded (e.g., surface-bonded or bonded with aloft-retaining bond) to the second surface of the thermoplastic backing.Impinging heated gaseous fluid onto the first surface of the fibrous weband impinging heated gaseous fluid on the second surface of the backingmay be carried out sequentially or simultaneously. Further methods andapparatus for joining a continuous web to a fibrous carrier web usingheated gaseous fluid may be found in U.S. Pat. Appl. Pub. Nos.2011/0151171 (Biegler et al.) and 2011/0147475 (Biegler et al.).

Referring again to FIG. 1C, the extensible carrier 30 may be continuous(i.e., without any through-penetrating holes) or discontinuous (e.g.comprising through-penetrating perforations or pores). The carrier maycomprise a variety of suitable materials including woven webs, non-wovenwebs, textiles, plastic films (e.g., single- or multilayered films,coextruded films, laterally laminated films, or films comprising foamlayers), and combinations thereof. The term “non-woven” refers to amaterial having a structure of individual fibers or threads that areinterlaid but not in an identifiable manner such as in a knitted fabric.Examples of non-woven webs include spunbond webs, spunlaced webs,airlaid webs, meltblown web, and bonded carded webs. In someembodiments, including embodiments in which the laminate is a mechanicalfastening laminate, the carrier is a fibrous material (e.g., a woven,nonwoven, or knit material). Useful fibrous materials may be made ofnatural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g.,thermoplastic fibers), or a combination of natural and synthetic fibers.Examples of suitable materials for forming thermoplastic fibers includepolyolefins (e.g., polyethylene, polypropylene, polybutylene, ethylenecopolymers, propylene copolymers, butylene copolymers, and copolymersand blends of these polymers), polyesters, and polyamides. The fibersmay also be multi-component fibers, for example, having a core of onethermoplastic material and a sheath of another thermoplastic material.In some embodiments, the carrier 30 comprises multiple layers ofnonwoven materials with, for example, at least one layer of a meltblownnonwoven and at least one layer of a spunbonded nonwoven, or any othersuitable combination of nonwoven materials. For example, the carrier 30may be a spunbond-meltbond-spunbond, spunbond-spunbond, orspunbond-spunbond-spunbond multilayer material. Or, the carrier 30 maybe a composite web comprising a nonwoven layer and a dense film layer. Avariety of combinations of film and nonwoven layers may be useful.Useful carriers 30 may have any suitable basis weight or thickness thatis desired for a particular application. For a fibrous carrier, thebasis weight may range, e.g., from at least about 5, 8, 10, 20, 30, or40 grams per square meter, up to about 400, 200, or 100 grams per squaremeter. The carrier 30 may be up to about 5 mm, about 2 mm, or about 1 mmin thickness and/or at least about 0.1, about 0.2, or about 0.5 mm inthickness.

In some embodiments of the laminates according to the present disclosureor made by a method according to the present disclosure, the carrier 30is elastic. In these embodiments, the carrier may be a film or fibrous.Examples of polymers for making elastic films or fibrous carriersinclude thermoplastic elastomers such as ABA block copolymers,polyurethane elastomers, polyolefin elastomers (e.g., metallocenepolyolefin elastomers), olefin block copolymers, polyamide elastomers,ethylene vinyl acetate elastomers, and polyester elastomers. An ABAblock copolymer elastomer generally is one where the A blocks arepolystyrenic, and the B blocks are prepared from conjugated dienes(e.g., lower alkylene dienes). The A block is generally formedpredominantly of substituted (e.g., alkylated) or unsubstituted styrenicmoieties (e.g., polystyrene, poly(alphamethylstyrene), orpoly(t-butylstyrene)), having an average molecular weight from about4,000 to 50,000 grams per mole. The B block(s) is generally formedpredominantly of conjugated dienes (e.g., isoprene, 1,3-butadiene, orethylene-butylene monomers), which may be substituted or unsubstituted,and has an average molecular weight from about 5,000 to 500,000 gramsper mole. The A and B blocks may be configured, for example, in linear,radial, or star configurations. An ABA block copolymer may containmultiple A and/or B blocks, which blocks may be made from the same ordifferent monomers. A typical block copolymer is a linear ABA blockcopolymer, where the A blocks may be the same or different, or a blockcopolymer having more than three blocks, predominantly terminating withA blocks. Multi-block copolymers may contain, for example, a certainproportion of AB diblock copolymer, which tends to form a more tackyelastomeric film segment. Other elastic polymers can be blended withblock copolymer elastomers, and various elastic polymers may be blendedto have varying degrees of elastic properties.

Many types of thermoplastic elastomers are commercially available,including those from BASF, Florham Park, N.J., under the tradedesignation “STYROFLEX”, from Kraton Polymers, Houston, Tex., under thetrade designation “KRATON”, from Dow Chemical, Midland, Mich., under thetrade designation “PELLETHANE”, “INFUSE”, VERSIFY”, or “NORDEL”, fromDSM, Heerlen, Netherlands, under the trade designation “ARNITEL”, fromE. I. duPont de Nemours and Company, Wilmington, Del., under the tradedesignation “HYTREL”, from ExxonMobil, Irving, Tex. under the tradedesignation “VISTAMAXX”, and more.

An elastic film may have a single layer of an elastomer, or the carriermay have a core made with an elastomer and at least one skin layer froma relatively non-elastic polymer, such as any of those described abovefor the thermoplastic backing. The materials and thicknesses of themulti-layer elastic carrier may be selected such that when the carrieris extended to a certain degree, the skin layers undergo plasticdeformation. When the elastic layer recovers, the relatively non-elasticskin layer forms a textured surface on the elastic core. Such elasticfilms are described, for example, in U.S. Pat. No. 5,691,034 (Krueger etal.).

Referring again to FIG. 1D, when the carrier 30 in the laminateaccording to the present disclosure or made according to the method ofthe present disclosure is elastic, the openings 22 are retractable. Asused herein, the term “retractable” can be understood to mean that astretching force in the second direction can increase the width of theopenings in the second direction, and release of the stretching forcecan at least partially close the plurality of openings to decrease thewidth of the openings in the second direction. Alternatively oradditionally, the term “retractable”, can be understood to mean that thethermoplastic backing is not macroscopically plastically deformed in thesecond direction. As such, it does not buckle when the stretching forceis released. A reticulated film in which the openings are made byplastic deformation of the film in a particular direction by definitiondoes not retract in that direction. Alternatively or additionally, theterm “retractable” can be understood to mean that the openings in thereticulated film are not formed by molding or hole-punching. It isunderstood by a person skilled in the art that an opening that is moldedor punched into a reticulated film is fixed in dimension by the moldingor hole-punching process, and the lack of material in the opening is notrecoverable. The retractable openings in the embodiment of the laminatedisclosed herein in which the carrier is elastic are thereforedistinguished from laminates of films that include openings formed bymolding or plastic deformation. Even if the elastic were stretched uponlaminating it to such a film, release of the stretching would result inbuckling of the film between openings.

In some embodiments, the carrier 30 is extensible but non-elastic. Inother words, the carrier may have an elongation of at least 25, 30, 40,or 50 percent but substantially no recovery from the elongation (e.g.,up to 10 or 5 percent recovery). Suitable extensible carriers mayinclude nonwovens (e.g., spunbond, spunbond meltblown spunbond, orcarded nonwovens). Thus, in these embodiments, typically the extensiblecarrier is deformed upon stretching in the second direction. In someembodiments, the nonwoven may be a high elongation carded nonwoven(e.g., HEC). Other extensible, non-elastic carriers includethermoplastic films, including those made from any of the materialsdescribed above for the thermoplastic backing. The extensible,non-elastic film may be thinner than the thermoplastic backing in someembodiments. In any of the embodiments in which the carrier 30 isextensible but non-elastic, stretching the laminate in the seconddirection generally both forms a tear in the thermoplastic backingbetween two of the discrete elements and maintains the openings in anopen configuration. However, the reticulated film itself may still haveretractable openings. This can be determined by removing the reticulatedfilm from the laminate, for example, peeling apart the carrier and thereticulated film. In some cases, removing the reticulated film from thelaminate can be facilitated by submerging the laminate in liquidnitrogen.

The reticulated films according to the present disclosure that areremoved from the carrier, for example, typically can also recover to atleast to some extent from a deformation in the second direction. Afterthe openings are formed, the openings provide regions in the reticulatedfilm where means for transmission of force in the second direction issubstantially absent. However, the locations where the thermoplasticbacking is joined together can still develop stress in the seconddirection when the reticulated film is strained in the second direction.The balance of the openings and the locations where the thermoplasticbacking is joined together provides the reticulated film with elasticbehavior, even though the thermoplastic itself is typically not anelastomer. Thus, there is a tendency for the reticulated film to retractafter being extended in the second direction if the thermoplasticbacking is not plastically deformed upon stretching in the seconddirection. This retraction can be amplified by applying tension in thefirst direction. This recovery from stretching would not be possible forreticulated films that are plastically deformed (providingstretch-induced molecular orientation) in the second direction. Withrespect to the stretched film shown in FIG. 1B, in some embodiments ofthe method according to the present disclosure, the reticulated film canrecover at least 70 or 75 and up to about 80 to 85 percent of itselongation after stretching in 2D upon release of the stretching forceand application of tension in 1D without plastically deforming the filmin 1D.

FIG. 5 illustrates another embodiment of the laminate 205 according tothe present disclosure and/or made according to the method of thepresent disclosure. In laminate 205, the carrier 230 that is laminatedto the partially reticulated film 201 comprises a first, extensible zone233 and a second, inextensible zone 235. The first, extensible zone 233underlies the openings 222, and the thermoplastic backing 214 overlyingthe second, inextensible zone 235 generally is not reticulated. In theseembodiments, the reticulated film 201 can be considered partiallyreticulated. In embodiments of the method according to the presentdisclosure, in which the carrier comprises a first, extensible zone 233and a second, inextensible zone 235, the tear between two adjacentdiscrete elements 210 is formed in the thermoplastic backing where itoverlies the first, extensible zone 233, and tearing generally does notoccur where the thermoplastic backing 214 overlies the second,inextensible zone 235. The film 201 is usually stretched in a firstdirection before lamination to the carrier 205, and the discreteelements 210, openings 222, and thermoplastic backing around theopenings 214 can have any of the features described in any of theaforementioned embodiments. Carriers 230 having first, extensible andsecond, inextensible zones can be formed in a variety of ways asdescribed below.

In some embodiments, carrier 230 is a film. Films comprising alternatingfirst, extensible zones and second, inextensible zones useful forpracticing the present disclosure can be made, for example, byside-by-side co-extrusion using any one of a number of useful methods.For example, U.S. Pat. No. 4,435,141 (Weisner et al.) describes a diewith die bars for making a multi-component film having alternatingsegments in the film cross-direction. A die bar, or bars, at the exitregion of the die segments two polymer flows using channels formed onthe two outer faces of the die bar. The two sets of segmented polymerflows within these channels converge at a tip of the die bar where thetwo die bar faces meet. The segmented polymer flows are arranged so thatwhen the two segmented polymer flows converge at the bar tip they formfilms that have alternating side-by-side zones of polymers. A similarprocess that further includes co-extruding a continuous outer skin layeron one or both outer faces of the side-by-side co-extruded film asdescribed in U.S. Pat. No. 6,669,887 (Hilston et al.) may also beuseful.

In some embodiments, management of the flow of different polymercompositions into side-by-side lanes to form a film such as carrier 230can be carried out using a single manifold die with a distribution platesuch as that described in, for example, in International PatentApplication Publication No. WO 2011/097436 (Gorman et al.), incorporatedby reference herein in its entirety. In some of these embodiments, thedie comprises a first die cavity in a first die portion, a second diecavity in a second die portion, a distribution plate interposed betweenat least a portion (e.g., most or all) of the first die cavity and atleast a portion (e.g., most or all) of the second die cavity. Thedistribution plate has a first side forming a boundary of the first diecavity, a second side forming a boundary of the second die cavity, adispensing edge, a plurality of first extrusion channels, and aplurality of second extrusion channels. The first extrusion channelsextend from entrance openings at the first die cavity to exit openingson the dispensing edge, and the second extrusion channels extend fromentrance openings at the second die cavity to exit openings on thedispensing edge. The exit openings of the first extrusion channels andthe exit openings of the second extrusion channels are disposed inalternating positions along the dispensing edge. Each of the firstextrusion channels comprises two opposite side walls and a joiningsurface connecting the two opposite side walls, and the joining surfaceof at least some of the first extrusion channels is typicallysubstantially parallel to the first side of the distribution plate.

Films comprising alternating first, extensible zones and second,inextensible zones useful for practicing the present disclosure such ascarrier 230 shown in FIG. 5 can also be made by other extrusion diesthat comprise a plurality of shims and have two cavities for moltenpolymer, such as those dies described, for example, in Int. Pat. App.Pub. No. WO 2011/119323 (Ausen et al.), incorporated herein by referencein its entirety. The plurality of shims positioned adjacent to oneanother together define first cavity, a second cavity, and a die slot,wherein the die slot has a distal opening wherein each of the pluralityof shims defines a portion of the distal opening. At least a first oneof the shims provides a passageway between the first cavity and the dieslot, and at least a second one of the shims provides a passagewaybetween the second cavity and the die slot. Typically, at least one ofthe shims is a spacer shim providing no conduit between either the firstor the second cavity and the die slot.

Other side-by-side coextrusion techniques that may be useful forproviding a film such as carrier 230 shown in FIG. 5 include thosedescribed in U.S. Pat. No. 6,159,544 (Liu et al.) and U.S. Pat. No.7,678,316 (Ausen et al.) and Int. Pat. App. Pub. No. WO 2011/119323(Ausen et al.).

Films comprising alternating first, extensible zones and second,inextensible zones useful for practicing the present disclosure includefilms wherein the second, inextensible zones are made from a relativelynon-elastic polymeric composition, and wherein the first, extensiblezones comprise strands of an elastic polymeric composition embedded in amatrix of the relatively non-elastic polymeric composition, in which thematrix is continuous with the second, inextensible zones. To make suchfilms an elastic polymer melt stream can be segmented into multiplesubstreams and then extruded into the center of a melt stream of therelatively non-elastic polymeric composition, which is then formed intoa film. This co-extrusion method creates a film that has multiplesegmented flows within a matrix of another polymer. Dies useful formaking films of this type include inclusion co-extrusion dies (e.g.,those shown in U.S. Pat. No. 6,767,492 (Norquist et al.) and U.S. Pat.No. 5,429,856 (Krueger et al.)) and other similar apparatuses.

Carriers comprising alternating first, extensible zones and second,inextensible zones useful for practicing the present disclosure can alsobe multi-layer films of an elastomeric layer and at least one relativelynon-elastic layer arranged in the film's thickness direction. Certainzones can be subjected to high heat and high pressure sufficient tocreate non-stretchable zones in the multi-layer film. In someembodiments, a coextruded multi-layer film can be stretched in across-machine direction to plastically deform the relatively non-elasticlayer, and the stretched film can be passed over a patterned heat roll(e.g., in a range from 65° C. to 85° C.) to form parallel non-elasticzones in the machine direction. Delamination of the non-elastic layer inthe elastic zones can be carried out, if desired, by cyclic heating andstretching and/or including additives in the non-elastic or elasticlayers that promote delamination. In these embodiments, the elasticzones can have unencumbered retraction when a stretching force isreleased. The non-elastic layer can have a corrugated appearance whenthe film is in a relaxed state. In some of these embodiments, thecarrier can be multi-layer such as that described in U.S. Pat. No.5,376,430 (Swenson et al.), for example.

Carriers comprising alternating first, extensible zones and second,inextensible zones useful for practicing the present disclosure can alsobe made by mechanical activation. Mechanical activation processesinclude stretching with diverging disks or incremental stretchingmethods such as ring-rolling, structural elastic film processing(SELFing), which may be differential or profiled, in which not allmaterial is strained in the direction of stretching, and other means ofincrementally stretching webs as known in the art. The mechanicallyactivated carrier may include films, fibrous layers, or combinationsthereof. Mechanical activation generally uses intermeshing surfaceshaving alternating peaks and valleys. In ring-rolling, corrugated rollsprovide the intermeshing surfaces through which the carrier is passed.The peaks can be defined as the apexes of outward pointing ridges of thecorrugated rolls when such apparatuses are used. In other embodiments,the intermeshing surfaces are intermeshing discs, which may be mounted,for example, at spaced apart locations along a shaft as shown, forexample, in U.S. Pat. No. 4,087,226 (Mercer). The intermeshing surfacescan also include rotating discs that intermesh with a stationary,grooved shoe. The peaks can also be defined as the peripheral surfaces(or center portion thereof) of the discs. In other incrementalstretching apparatuses, the peaks of one of the intermeshing surfaceswould be readily identifiable to a person skilled in the art.

An example of a suitable mechanical activation process is thering-rolling process, described in U.S. Pat. No. 5,366,782 (Curro).Specifically, a ring-rolling apparatus includes opposing rolls havingintermeshing teeth that incrementally stretch and thereby plasticallydeform the fibrous web or a portion thereof forming the outer cover,thereby rendering the outer cover stretchable in the ring-rolledregions. Activation performed in a single direction (for example thecross direction) yields an outer cover that is uniaxially stretchable.Activation performed in two directions (for example the machine andcross directions or any two other directions maintaining symmetry aroundthe outer cover centerline) yields an outer cover that is biaxiallystretchable.

In embodiments of the laminate or method according to the presentdisclosure in which the carrier has first, extensible zones and second,inextensible zones, the nature of the openings in the reticulated filmthat overly the extensible zones will be affected by the carrier asdescribed above. Referring again to FIG. 5, when the extensible zones233 of carrier 230 in laminate 200 are elastic, the openings 222 areretractable as described above. When the extensible zones 233 of carrier230 in laminate 200 are non-elastic, extensible zones 233 typicallymaintain the openings 222 in an open configuration as described above.

Any of the machine direction and cross-direction methods described abovecan be useful for stretching the laminate in the second direction.Stretching the laminate, particularly in the second direction, may alsobe carried out by hand, for example. As described above, when stretchingthe laminate, stretching forces are exerted mainly on the extensiblecarrier. As a result, stretching a laminate in the second direction 2Dcan be carried out at least ten times faster than stretching thethermoplastic film itself. In some embodiments, stretching in the seconddirection can be carried out at a speed of at least up 15 centimetersper minute, at least 20 centimeters per minute, or at least 25centimeters per minute. In some embodiments, stretching in the seconddirection can be carried out at a speed up to about 50 centimeters perminute or more.

In some embodiments of the method according to the present disclosure,laminating the thermoplastic backing to the carrier to provide thelaminate is carried out before stretching the thermoplastic backing inthe first direction. In these embodiments, in addition to each of themethods of joining the thermoplastic backing to the carrier describedabove (e.g., continuous or discontinuous thermal bonding, continuous ordiscontinuous adhesive bonding, ultrasonic bonding, compression bonding,or surface bonding) laminating the thermoplastic backing to the carriercan also be carried out by extrusion lamination. In some of theseembodiments, the carrier is a fibrous carrier. For these embodiments,any of the machine direction and cross-direction stretching methodsdescribed above can be used sequentially for stretching in the firstdirection and subsequently the second direction in the method accordingto the present disclosure. A versatile stretching method that allows formonoaxial and sequential biaxial stretching of a thermoplastic webemploys a flat film tenter apparatus. Such an apparatus grasps thethermoplastic web using a plurality of clips, grippers, or other filmedge-grasping means along opposing edges of the thermoplastic web insuch a way that monoaxial and biaxial stretching in the desireddirection is obtained by propelling the grasping means at varying speedsalong divergent rails. Increasing clip speed in the machine directiongenerally results in machine-direction stretching. Stretching at anglesto the machine direction and cross-direction are also possible with aflat film tenter appararus. Monoaxial and biaxial stretching can also beaccomplished, for example, by the methods and apparatus disclosed inU.S. Pat. No. 7,897,078 (Petersen et al.) and the references citedtherein. Flat film tenter stretching apparatuses are commerciallyavailable, for example, from Brückner Maschinenbau GmbH, Siegsdorf,Germany.

In some embodiments, the method according to the present disclosurefurther comprises heating the thermoplastic backing. Heating may beuseful, for example, before or during the stretching in the firstdirection. This may allow the thermoplastic backing to be more flexiblefor stretching. The temperature to which the thermoplastic backing isheated while stretching in the first direction may also affect theuniformity achieved when the backing is stretched in the seconddirection. In some embodiments in which the thermoplastic backing is apolypropylene backing, stretching in the first direction is carried outin a temperature range from 80° C. to 110° C., 85° C. to 100° C., or 90°C. to 95° C.

Heating may also be useful, for example, before, during, or afterstretching in the second direction. The force that is needed to tear andspread the film in the second direction decreases when the film isgently heated during this step. Also, the appearance of the reticulatedfilm is changed when the film is heated while stretching in the seconddirection as shown in pictures shown in FIGS. 6A and 6B. FIG. 6A is apicture of an embodiment of the reticulated film according to thepresent disclosure in which the thermoplastic backing was not heatedwhile stretching in the second direction. FIG. 6B is a picture of anembodiment of the reticulated film according to the present disclosurein which the same thermoplastic backing was heated to maintain aconstant load while stretching in the second direction. The strand widthin the reticulated film is typically larger when the backing is heatedthan when it is not heated. Also, the openings have sides that are morecurved and corners that are more rounded when the backing is heated thanwhen it is not heated. In some of these embodiments, the openings mayhave an approximately vesica piscis shape, which may also be consideredan almond shape. Like the quadrilateral shape described above, the shapeof the openings observed when the film is heated in the second directionstill has two axis of symmetry, one in 1D and one in 2D. As can beobserved in FIG. 6B, there are two discrete elements abutting oppositeends of any given opening (the more rounded extremes of the vesicapiscis or almond shape), and there is one discrete element between thegiven opening and an adjacent opening aligned in the second direction(beyond the more pointed ends of the vesica piscis or almond shape).

In some embodiments, the laminate according to and/or made according tothe present disclosure can be heated, for example, after stretching inthe second direction. Heating at such a time may be useful for annealingthe reticulated film, for example, to maintain the openings and tomaintain the planarity of the thermoplastic backing, which may beuseful, for example, if the reticulated film is to be removed from thecarrier after the openings are formed and/or if the extensible carrieris elastic. In some embodiments, annealing comprises heating and thencooling (e.g., rapidly cooling) the laminate or reticulated film.

For any of these purposes, heating can be provided, for example, by IRirradiation, hot air treatment or by performing the stretching orannealing in a heat chamber. Rollers that may be used for stretching thethermoplastic backing in at least one of the first or second directionsmay be heated. Heated rollers may also be useful, for example, forannealing the reticulated film. For annealing, a continuous reticulatedfilm can also be directed onto a chilled roller for rapid cooling. Insome embodiments, heating is only applied to the second surface of thethermoplastic backing (i.e., the surface opposite the first surface fromwhich the discrete elements protrude and the surface to which thecarrier is joined) to minimize any damage to the discrete elements thatmay result from heating. For example, in these embodiments, only rollersthat are in contact with the second surface of the thermoplastic backingor the carrier are heated. Heating is typically only carried out belowthe melting temperature of the thermoplastic backing.

Other web handling techniques may be useful for the laminate accordingto and/or made according to the method of the present disclosure afterit is stretched in the second direction. For example, it may be usefulto direct the reticulated film onto a high-friction roller or otherhigh-friction surface to maintain the openings.

As described herein, laminating the thermoplastic backing to theextensible carrier before stretching in the second direction can beuseful since some of the force of stretching is exerted on theextensible carrier. An illustration of the different mechanisms ofstretching the thermoplastic backing, with and without a carrier, isshown in FIGS. 7A and 7B. A sample of a laminate similar to that shownin FIG. 1C was placed between the jaws of a tensile tester obtained fromInstron, Norwood, Mass. The sample was stretched at a speed of 25.4 cm(10 inches) per minute to an extension of 5.08 cm (2 inches) in a loadrange from 3 to 6 lbf (13.3 N to 26.7 N). For comparison, a sample of athermoplastic backing similar to that shown in FIG. 1B was stretched thesame way. The sample was stretched at a speed of 2.54 cm (1 inch) perminute to 5.08 cm (1 inch per minute) to an extension of 4.19 cm (1.65inches) with a load of about 2 lbf (8.9 N). The laminate can handle ahigher load and be stretched at a faster rate. An expansion of thetensile extension vs. load curve for the non-laminated thermoplasticbacking is shown in FIG. 7B. As shown in FIG. 7B, the load drops whenthe first tear forms, and a subsequent rise and drop of the loadcorrespond to the formation of several tears in the reticulated film. Incontrast, an expansion of the tensile extension vs. load curve for thelaminate is shown in FIG. 7A. The load increases as each tear is formed,with a leveling in between. Since stresses can be handled by thecarrier, the laminate can handle increasing load as the reticulated filmis formed.

When the laminate according to the present disclosure is in the form ofa continuous web, the laminate can be cut in the cross-machinedirection, for example, to provide a patch of any desired size for agiven application. When the discrete elements are male fasteningelements, the patch can be considered a fastening patch or fasteninglaminate.

Fastening laminates made by the methods disclosed herein are useful, forexample, in absorbent articles. Absorbent articles may have at least afront waist region, a rear waist region, and a longitudinal center linebisecting the front waist region and the rear waist region, wherein atleast one of the front waist region or the rear waist region comprisesthe fastening laminate disclosed herein. The fastening laminate may bein the form of a fastening tab or landing zone that is bonded to atleast one of the front waist region or the rear waist region. Afastening tab may extend outwardly from at least one of the leftlongitudinal edge or the right longitudinal edge of the absorbentarticle. In other embodiments, the fastening laminate may be an integralear portion of the absorbent article. The carrier at the user's end of afastening tab may exceed the extension of the mechanical fastening patchthereby providing a fingerlift. When the laminate disclosed herein isused in a fastening tab, exposed adhesive that may be present in someembodiments in at least some of the openings in the reticulated film maybe useful for “anti-flagging” or for maintaining the disposableabsorbent article in a rolled up state after use. The fastening laminatemade by the methods disclosed herein may also be useful, for example,for disposable articles such as sanitary napkins. Mechanical fastenersand laminates made according to the present disclosure may also beuseful in many other fastening applications, for example, assembly ofautomotive parts or any other application in which releasable attachmentmay be desirable.

Laminates according to the present disclosure and/or made according tothe method of the present disclosure may also be useful as reflectivesurfaces for a variety of optical applications. For example, thediscrete elements may be prisms (e.g., triangular, rectangular, rhombic,or hexagonal prisms), pyramids, or have a cross-section of adodecahedral cross, any of which may be made according to the methodsdescribed above. A reticulated film as a prismatic reflective surfacewill tend to have a lower material cost than prismatic reflectivesurfaces made with a continuous film backing.

Reticulated thermoplastic films useful in the laminates according to thepresent disclosure and/or made according to the present disclosure arealso described in U.S. Pat. App. Pub. No. 2014/0349062 (Chandrasekaranet al.), incorporated by reference herein in its entirety.

Some Embodiments of the Disclosure

In a first embodiment, the present disclosure provides a laminatecomprising an at least partially reticulated thermoplastic film joinedto an extensible carrier, the at least partially reticulatedthermoplastic film comprising a thermoplastic backing comprising firstand second major surfaces, a plurality of openings in the thermoplasticbacking, and a plurality of discrete elements protruding from the firstmajor surface of the thermoplastic backing, wherein there are twodiscrete elements abutting opposite ends of any given opening, whereinthe two discrete elements are aligned in a first direction, whereinthere is one discrete element between the given opening and an adjacentopening aligned in a second direction perpendicular to the firstdirection, wherein each portion of the thermoplastic backing around thegiven opening is plastically deformed in its lengthwise direction.

In a second embodiment, the present disclosure provides the laminate ofthe first embodiment, wherein at least some of the discrete elementseach comprise one upstanding post.

In a third embodiment, the present disclosure provides the laminate ofthe first embodiment, wherein at least some of the discrete elementscomprise more than one upstanding post on a surface protrusion.

In a fourth embodiment, the present disclosure provides the laminate ofthe second or third embodiment, wherein the upstanding post is part of amale fastening element.

In a fifth embodiment, the present disclosure provides the laminate ofthe fourth embodiment, wherein the male fastening element furthercomprises a cap distal from the thermoplastic backing.

In a sixth embodiment, the present disclosure provides the laminate ofany one of the first to fifth embodiments, wherein the discrete elementsprotrude only from the first major surface of the thermoplastic backing.

In a seventh embodiment, the present disclosure provides the laminate ofany one of the first to sixth embodiments, wherein the discrete elementshave a height above the thermoplastic backing of at least 30micrometers.

In an eighth embodiment, the present disclosure provides the laminate ofany one of the first to seventh embodiments, wherein the thermoplasticbacking is substantially uniform in thickness.

In a ninth embodiment, the present disclosure provides the laminate ofany one of the first to eighth embodiments, wherein the thermoplasticbacking is substantially planar.

In a tenth embodiment, the present disclosure provides the laminate ofany one of the first to ninth embodiments, wherein at a point at an edgeof the given opening, the thermoplastic backing has a higherstretch-induced molecular orientation than at a midpoint of the portionof the thermoplastic backing around the given opening.

In an eleventh embodiment, the present disclosure provides the laminateof any one of the first to tenth embodiments, wherein the plurality ofdiscrete elements are arranged in a staggered array when viewed in thefirst direction.

In a twelfth embodiment, the present disclosure provides the laminate ofany one of the first to eleventh embodiments, wherein the at leastpartially reticulated thermoplastic film is joined to the extensiblecarrier with adhesive.

In a thirteenth embodiment, the present disclosure provides the laminateof any one of the first to twelfth embodiments, wherein the extensiblecarrier is non-elastic.

In a fourteenth embodiment, the present disclosure provides the laminateof any one of the first to twelfth embodiments, wherein the extensiblecarrier is an elastic carrier, and wherein the given opening opens andcloses upon extension and retraction of the elastic carrier.

In a fifteenth embodiment, the present disclosure provides the laminateof any one of the first to twelfth embodiments, wherein the first,extensible zone underlies the openings, and wherein the thermoplasticbacking overlying the second, non-extensible zone is not reticulated.

In a sixteenth embodiment, the present disclosure provides an absorbentarticle comprising the laminate of any one of the first to fifteenthembodiments.

In a seventeenth embodiment, the present disclosure provides method ofmaking the laminate of any one of the first to fifteenth embodiments,the method comprising:

providing a thermoplastic backing comprising first and second majorsurfaces and a plurality of discrete elements protruding from the firstmajor surface of the thermoplastic backing, wherein the two discreteelements are aligned in a row in a first direction;

stretching the thermoplastic backing in the first direction toplastically deform the thermoplastic backing and separate the at leastsome of the discrete elements aligned in the row in the first direction,wherein the thermoplastic backing remains intact between the pluralityof discrete elements after stretching it in the first direction;

laminating the thermoplastic backing to an extensible carrier to providea laminate, wherein the extensible carrier is extensible in at least asecond direction perpendicular to the first direction; and

stretching the laminate in the second direction to form a tear in thethermoplastic backing between two adjacent of the discrete elementsaligned in the row in the first direction, wherein the tear isinterrupted by the two adjacent of the discrete elements, and whereinthe tear provides the given opening. A plurality of the tears providesthe plurality of openings.

In an eighteenth embodiment, the present disclosure provides the methodof the seventeenth embodiment, wherein after stretching in the seconddirection, the thermoplastic backing has a thickness that issubstantially the same as before stretching in the second direction.

In a nineteenth embodiment, the present disclosure provides the methodof the seventeenth or eighteenth embodiment, wherein laminating thethermoplastic backing to the extensible carrier is carried out beforestretching the thermoplastic backing in the first direction.

In a twentieth embodiment, the present disclosure provides the method ofthe seventeenth or eighteenth embodiment, wherein laminating thethermoplastic backing to the extensible carrier is carried out afterstretching the thermoplastic backing in the first direction.

In a twenty-first embodiment, the present disclosure provides a methodof making a laminate, the method comprising:

providing a thermoplastic backing comprising first and second majorsurfaces and a plurality of discrete elements protruding from the firstmajor surface of the thermoplastic backing, wherein at least some of thediscrete elements are aligned in a row in a first direction;

stretching the thermoplastic backing in the first direction to a degreesufficient to plastically deform the thermoplastic backing and separatethe at least some of the discrete elements aligned in the row in thefirst direction, wherein the thermoplastic backing remains intactbetween the plurality of discrete elements after stretching it in thefirst direction;

laminating the thermoplastic backing to an extensible carrier to providea laminate, wherein the extensible carrier is extensible in at least asecond direction perpendicular to the first direction; and

stretching the laminate in the second direction to form a tear in thethermoplastic backing between two adjacent of the discrete elementsaligned in the row in the first direction, wherein the tear isinterrupted by the two adjacent of the discrete elements.

In a twenty-second embodiment, the present disclosure provides themethod of the twenty-first embodiment, wherein at least some of thediscrete elements each comprise one upstanding post.

In a twenty-third embodiment, the present disclosure provides the methodof the twenty-first embodiment, wherein at least some of the discreteelements comprise more than one upstanding post on a surface protrusion.

In a twenty-fourth embodiment, the present disclosure provides themethod of the twenty-second or twenty-third embodiment, wherein theupstanding post is part of a male fastening element.

In a twenty-fifth embodiment, the present disclosure provides the methodof the twenty-fourth embodiment, wherein the male fastening elementfurther comprises a cap distal from the thermoplastic backing.

In a twenty-sixth embodiment, the present disclosure provides the methodof any one of the twenty-first to twenty-fifth embodiments, wherein thediscrete elements protrude only from the first major surface of thethermoplastic backing.

In a twenty-seventh embodiment, the present disclosure provides themethod of any one of the twenty-first to twenty-sixth embodiments,wherein the discrete elements have a height above the thermoplasticbacking of at least 30 micrometers.

In a twenty-eighth embodiment, the present disclosure provides themethod of any one of the twenty-first to twenty-seventh embodiments,wherein the thermoplastic backing is substantially uniform in thickness.

In a twenty-ninth embodiment, the present disclosure provides the methodof any one of the twenty-first to twenty-eighth embodiments, wherein thethermoplastic backing is substantially planar.

In a thirtieth embodiment, the present disclosure provides the method ofany one of the twenty-first to twenty-ninth embodiments, wherein at apoint at an edge of the given opening, the thermoplastic backing has ahigher stretch-induced molecular orientation than at a midpoint of theportion of the thermoplastic backing around the given opening.

In a thirty-first embodiment, the present disclosure provides the methodany one of the twenty-first to thirtieth embodiments, wherein theplurality of discrete elements are arranged in a staggered array whenviewed in the first direction.

In a thirty-second embodiment, the present disclosure provides themethod of any one of the twenty-first to thirty-first embodiments,wherein after stretching in the second direction, the thermoplasticbacking has a thickness that is substantially the same as beforestretching in the second direction.

In a thirty-third embodiment, the present disclosure provides the methodof any one of the twenty-first to thirty-second embodiments, whereinlaminating the thermoplastic backing to the extensible carrier iscarried out before stretching the thermoplastic backing in the firstdirection.

In a thirty-fourth embodiment, the present disclosure provides themethod of any one of the twenty-first to thirty-second embodiments,wherein laminating the thermoplastic backing to the extensible carrieris carried out after stretching the thermoplastic backing in the firstdirection.

In a thirty-fifth embodiment, the present disclosure provides the methodof any one of the twenty-first to thirty-fourth embodiments, wherein theextensible carrier is elastic.

In a thirty-sixth embodiment, the present disclosure provides the methodof any one of the twenty-first to thirty-fourth embodiments, wherein theextensible carrier is deformed upon stretching in the second direction.

In a thirty-seventh embodiment, the present disclosure provides themethod of any one of the twenty-first to thirty-fourth embodiments,wherein the carrier comprises a first, extensible zone and a second,non-extensible zone, and wherein the tear is formed in the thermoplasticbacking where it overlies the first, extensible zone.

In a thirty-eighth embodiment, the present disclosure provides themethod of any one of the seventeenth to thirty-seventh embodiments,wherein laminating the thermoplastic backing to the extensible carriercomprises adhering the thermoplastic backing and the extensible carriertogether.

In a thirty-ninth embodiment, the present disclosure provides the methodof any one of the seventeenth to thirty-eighth embodiments, wherein adensity of the discrete elements is in a range from 20 per cm² to 1000per cm².

In a fortieth embodiment, the present disclosure provides the method ofany one of the seventeenth to thirty-ninth embodiments, furthercomprising heating the thermoplastic backing while stretching it in thefirst direction.

In a forty-first embodiment, the present disclosure provides the methodof any one of the seventeenth to fortieth embodiments, furthercomprising heating the thermoplastic backing while stretching it in thesecond direction.

In a forty-second embodiment, the present disclosure provides the methodof any one of the seventeenth to forty-first embodiments, furthercomprising annealing the thermoplastic backing after stretching it inthe second direction.

In a forty-third embodiment, the present disclosure provides thelaminate of any one of the first to fifteenth embodiments, the absorbentarticle of the sixteenth embodiment, or the method of any one of theseventeenth to forty-second embodiments, wherein the plurality ofopenings have a diamond or almond shape.

In a forty-fourth embodiment, the present disclosure provides thelaminate of any one of the first to fifteenth embodiments, the absorbentarticle of the sixteenth embodiment, or the method of any one of theseventeenth to forty-third embodiments, wherein the thermoplasticbacking comprises at least one of polypropylene or polyethylene.

In order that this disclosure can be more fully understood, thefollowing examples are set forth. It should be understood that theseexamples are for illustrative purposes only and are not to be construedas limiting this disclosure in any manner.

EXAMPLES Illustrative Example 1

A thermoplastic backing with upstanding capped posts was prepared byfeeding a stream of a film grade polypropylene copolymer, apolypropylene impact copolymer obtained from Dow Chemical Company,Midland, Mich., under the trade designation “DOW C700-35N POLYPROPYLENERESIN” through a 2-inch (5.1-cm) single screw extruder. Barrel zones 1-7were set at 176° C., 170° C., 180° C., 190° C., 200° C., 218° C., and218° C., respectively. The molten resin was then fed through a sheet dieto a rotating cylindrical mold. The temperature of the die was set at216° C. (420° F.), and the temperature of cylindrical mold was set at71° C. (160° F.). The screw speed was set at 80 rpm. The mold waswater-cooled to provide rapid quenching that maintained the orientationin the polymer. The post density was 1600 posts per square inch (248posts per square centimeter) arranged in a staggered array when viewedin the machine direction, and the post shape was conical. Thecross-sectional shape of the post at the base was circular with adiameter of 350 micrometers. The line speed was set such that the filmthickness was 100 micrometers. The web was fed into a cap formingapparatus after slitting it to the width to fit the apparatus. The postswere capped with oval shaped caps using the procedure described in U.S.Pat. No. 5,845,375 (Miller et al.). The caps were subsequently deformedusing the procedure described in U.S. Pat. No. 6,132,660 (Kampfer) toprovide “hook heads with downwardly projecting fiber engaging portions”.

Stretching in the first direction was carried out by passing the webthrough two sets of rolls in which one roll was rotating faster that theother one. For each set of rolls, the bottom roll was a chrome roll, andthe top roll was a rubber roll. For stretching, the temperature of eachbottom chrome roll was set at 127° C. (260° F.) and that of each toprubber roll was set at 93° C. (200° F.). The draw ratio was 3.2 in themachine direction. A 3.8-cm (1.5-inch) wide sample was subsequentlystretched in the cross direction in the jaws of a tensile testerobtained from Instron, Norwood, Mass., under the trade designation“INSTRON 5500R” with 2.54 cm gauge length. The sample was stretched atrate of 2.54 cm (1 inch)/minute to a final width of 7.6 cm (3 inches). Areticulated film such as that shown in FIGS. 1D and 2 was formed.

Illustrative Examples 2 to 7

Illustrative Examples 2 to 7 were made according to the methods ofIllustrative Example 1, with the modification that various draw ratioswere used for the machine direction stretching of various rolls. Thedraw ratios were varied from 1 to 4 in increments of 0.2. At draw ratiosof 2.2 and less, stretching in the cross direction did not form a netbut instead formed a biaxially stretched continuous film. Aftercross-direction stretching at 2.4 and higher, the film was reticulated.

The basis weight for each sample was measured before and aftercross-direction stretching by punching out a 100-cm² sample from thereticulated film using a 25 cm by 4 cm punch. The sample was weighed onan electronic, analytical balance obtained from Mettler-ToledoInternational, Inc., Columbus, Ohio. The weight was multiplied by 100 tocalculate the basis weight in grams per square meter (gsm).

The strand width of the reticulated film was measured by opticalmicroscope obtained from Keyence Corporation of America, Elmwood Park,N.J., under the trade designation “VHX-100”. Ten measurements were takenand averaged.

The draw ratio used for each Illustrative Example, the basis weightbefore and after cross-direction stretching, and the average strandwidth are shown in Table 1, below.

TABLE 1 Basis Weight Basis Weight Illustrative Draw (gsm) before CD(gsm) after CD Strand Width Example Ratio stretch stretch (micrometers)1 3.2 60.1 41.8 400 2 2.4 71.8 49.4 482 3 2.6 68.8 47.5 460.7 4 2.8 66.246 442.3 5 3.0 62.0 44.2 411.1 6 3.4 58.2 40.2 398.7 7 3.8 52.8 39.2363.2

A reticulated film made according to the method of Illustrative Example1 was cut in the cross-direction across lines corresponding to “a” and“b” shown in FIG. 1D. Four small specimens were cut from thethermoplastic backing portions cut at line “a” and line “b”. Each of thefour specimens was dip-coated in epoxy. After curing for at least 24hours, the epoxy-bound samples were microtomed to yield 10-μm-thicksections of epoxy and net that transected the net legs. The microtomedsections were placed on glass slides with 1.515 refractive index oil andcovered with a cover slip. A DMRXE microscope (Leica Microsystems GmbH,Wetzlar, Germany) with a 10×/0.25 objective was equipped with anLC-POLSCOPE retardance imaging system (Lot-Oriel GmBH & Company,Darmstadt, Germany); a RETIGA EXI FAST 1394 digital color camera(QIMAGING, Surrey BC, Canada); and a 546.5 nm interference filter(Cambridge Research and Instrumentation, Inc., Hopkinton, Mass.). Foreach specimen, the imaging system was set to record the averageretardance of a 7336-pixel imaging, an azimuth map, a horizontal linescan, and a false-color retardance map. Retardance is proportional tobirefringence. The color photographs were converted to black and white.Areas of lighter color indicate areas of higher birefringence. Two ofthe photographs showed areas of higher birefringence at the edges (thosecorresponding to the right portion cut at line “a” and the left portioncut at line “b” in FIG. 1D. These are shown in FIGS. 3C and 3D. Theother two photographs showed less difference across the thermoplasticbacking portion.

Illustrative Examples 8 to 13

Illustrative Examples 8 to 13 were made according to the methods ofIllustrative Example 1, with the modifications that the post density was6000 posts per square inch (930 posts per square centimeter) and thatvarious draw ratios were used for the machine direction stretching ofvarious rolls as described in Illustrative Examples 2 to 7. The drawratios were varied from 1 to 4 in increments of 0.2. At draw ratios of3.0 and less, stretching in the cross direction did not form a net butinstead formed a biaxially stretched continuous film. The basis weightfor each sample was measured before cross-direction stretching using themethod described in Illustrative Examples 2 to 7. After cross-directionstretching, the strand width of the reticulated film was measured byoptical microscope using the method described in Illustrative Examples 2to 7. The draw ratio used for each Illustrative Example, the basisweight before stretching, and the average strand width aftercross-direction stretching are shown in Table 2, below.

TABLE 2 Illustrative Draw Basis Weight (gsm) Strand Width Example Ratiobefore CD stretch (micrometers) 8 3.2 58.6 276.3 9 3.4 56.3 255.5 10 3.655.2 250.8 11 3.8 53.3 231.5 12 4.0 52.7 217.2 13 4.2 52.3 213.8

Illustrative Examples 14 to 21

Illustrative Examples 14 to 21 were made according to the methods ofIllustrative Example 1, with the modifications that the thickness of thethermoplastic backing was either 70 micrometers or 130 micrometers. Thethickness of the thermoplastic backing was altered by using the samemass of material extruded from the die but increasing the line speed.Various draw ratios were used for the machine direction stretching ofvarious rolls as described in Illustrative Examples 2 to 7. The drawratios were varied from 1 to 4 in increments of 0.2. At draw ratios of1.8 and less for a 70-micrometer film and 2.6 and less for a130-micrometer film, stretching in the cross direction did not form anet but instead formed a biaxially stretched continuous film. The basisweight for each sample was measured after cross-direction stretchingusing the method described in Illustrative Examples 2 to 7. Aftercross-direction stretching, the strand width of the reticulated film wasmeasured by optical microscope using the method described inIllustrative Examples 2 to 7. The draw ratios and thermoplastic backingthickness used for each Illustrative Example, the basis weight aftercross-direction stretching, and the average strand width aftercross-direction stretching are shown in Table 3, below.

TABLE 3 Basis Weight Illustrative Thickness Draw (gsm) after CD StrandWidth Example (micrometers) Ratio stretch (micrometers) 14 70 2.0 58.8526.6 15 70 2.2 45.0 480.3 16 70 2.4 44.2 448.8 17 130 2.8 50.0 470.0 18130 3.2 35.6 404.8 19 130 3.4 33.7 404.0 20 130 3.6 32.0 388.5 21 130 431.1 367.2

Illustrative Examples 22 to 27

Illustrative Examples 22 to 27 were made according to the methods ofIllustrative Example 1, with the modifications that a different mold wasused so that the diameter of the post at the base was 250 micrometers.Various draw ratios were used for the machine direction stretching ofvarious rolls as described in Illustrative Examples 2 to 7. The drawratios were varied from 1 to 4 in increments of 0.2. At draw ratios of2.8 and less, stretching in the cross direction did not form a net butinstead formed a biaxially stretched continuous film. The basis weightfor each sample was measured before cross-direction stretching using themethod described in Illustrative Examples 2 to 7. After cross-directionstretching, the strand width of the reticulated film was measured byoptical microscope using the method described in Illustrative Examples 2to 7. The draw ratios used for each Illustrative Example, the basisweight before cross-direction stretching, and the average strand widthafter cross-direction stretching are shown in Table 4, below.

TABLE 4 Illustrative Draw Basis Weight (gsm) Strand Width Example Ratiobefore CD stretch (micrometers) 22 3.0 56.5 451.2 23 3.2 54.5 423.8 243.4 52.9 419.8 25 3.6 52.1 410.3 26 3.8 51.8 396.6 27 4.0 48.4 371.6

Illustrative Examples 28 to 39

Illustrative Examples 28 to 39 were made according to the methods ofIllustrative Example 1, with the modification that high densitypolyethylene (H6030) (PE) obtained from LyondellBasell Industries,Houston, Tex., was used instead of polypropylene (PP). Various drawratios were used for the machine direction stretching of various rollsas described in Illustrative Examples 2 to 7 except the draw ratios werevaried from 3 to 4 in increments of 0.2. The basis weight for eachsample was measured before cross-direction stretching using the methoddescribed in Illustrative Examples 2 to 7. After cross-directionstretching, the strand width of the reticulated film was measured byoptical microscope using the method described in Illustrative Examples 2to 7. The draw ratios and thermoplastic used for each IllustrativeExample, the basis weight before cross-direction stretching, and theaverage strand width after cross-direction stretching are shown in Table5, below.

TABLE 5 Illustrative Draw Basis Weight (gsm) Strand Width ExampleThermoplastic Ratio before CD stretch (micrometers) 28 PE 3 66.5 467.329 PE 3.2 62.6 454.8 30 PE 3.4 56.7 449.2 31 PE 3.6 54.4 437.6 32 PE 3.851.5 417.8 33 PE 4 51.2 409.5 34 PP 3 56.5 451.1 35 PP 3.2 54.5 423.8 36PP 3.4 52.9 419.8 37 PP 3.6 52.1 410.3 38 PP 3.8 51.8 396.6 39 PP 4 48.4371.6

Illustrative Example 40

Illustrative Example 40 was prepared from a film extruded, molded withposts that were subsequently capped, and stretched in the machinedirection according to the method of Illustrative Example 1. Twodifferent punches were used to punch four samples from the film. The twopunches were 37 mm by 25 mm and 30 mm by 20 mm, respectively. Twosamples were prepared from the first punch with the 37-mm edges alignedin the machine direction, and one sample was prepared from the firstpunch with the 37-mm edges aligned in the cross-machine direction. Onesample was prepared from the second punch with its 30-mm edges alignedin the machine direction. Each sample was stretched by hand in thecross-direction to two times its width, and a reticulated film wasformed. The length and width of each sample were measured. Next eachsample was pulled by hand in the machine direction to place some tensionon the film. The length and width of each sample were measured again.The original length (L) and width (W) of each sample, the length andwidth of each sample after stretching in the width direction to make thereticulated film, and the length and width of each sample after tensionwas applied on the reticulated film in the machine direction are shownin Table 6, below.

TABLE 6 Stretched/ Tensioned/ Original (1) Stretched (2) OriginalTensioned (3) Original L (mm) W (mm) L (mm) W (mm) L2/L1 W2/W1 L (mm) W(mm) L3/L1 W3/W1 37 25 27 50 0.73 2 36 31 0.97 1.24 37 25 28 50 0.76 237 30 1.00 1.20 25 37 20 74 0.80 2 23 45 0.92 1.22 30 20 25 39 0.83 1.9529 24 0.97 1.20 The recovery from stretching can be calculated from theequation (W2 − W1) − (W3 − W1)/(W2 − W1). The percent recoveries for thesamples were 76%, 80%, 78%, and 79%, respectively.

Illustrative Example 41

Illustrative Example 41 was prepared from a film extruded, molded withposts that were subsequently capped, and stretched in the machinedirection according to the method of Illustrative Example 1. A piece2.54 cm long and 12.5 cm wide was cut from the film and placed betweenthe jaws of a tensile tester obtained from Instron, Norwood, Mass.,under the trade designation “INSTRON 5500R” with 2.54 cm gauge length.The sample was stretched at a speed of about 2.54 cm (1 inch) per minuteto a length of 13.5 cm. A heat gun was used to intermittently heat thesample to keep the load on the sample approximately constant at 6 pounds(8.9 N). A picture of the reticulated film was taken with the opticalmicroscope obtained from Keyence Corporation of America under the tradedesignation “VHX-100” and in shown in FIG. 6B. For comparison, a samplestretched at room temperature as in Illustrative Example 1 is shown inFIG. 6A.

Illustrative Example 42

Illustrative Example 42 was prepared from a film extruded, molded withposts that were subsequently capped, and stretched in the machinedirection according to the method of Illustrative Example 1. A 2 cm by 2cm sample of the film was examined with a polarization microscope “LEICADM2700P”, obtained from Microsystems GmbH, Wetzlar, Germany. Themicroscope was equipped with cross polars and was used in transmissionmode. The polarizer and analyzer were placed at 90 degrees to each otherfor dark field imaging. The sample was placed between the polarizer andanalyzer, and a 50× image was recorded using a digital microscope camera“PROGRES C3”, obtained from Jenoptik Optical Systems, GmbH, Jena,Germany, with the focus on the thermoplastic backing. The colorphotograph was converted to grayscale and is shown in FIG. 3A. In thecolor image, the areas with highest birefringence appeared orange, andin the grayscale photograph shown in FIG. 3A, these areas appear as thedarker, triangular areas above and below the round upstanding elementsreveals. The sample was then stretched by hand in the cross-machinedirection to form a reticulated film, and the sample was imaged usingthe polarization microscope under the same conditions as the samplebefore stretching in the second direction. The color photograph wasconverted to grayscale and is shown in FIG. 3B. Areas of lighter color,which are on the edges of the thermoplastic backing portions around theopenings, indicate areas of higher birefringence. Although not visiblein the gray scale image of FIG. 3B, the highest birefringence appearedorange and was located in the thermoplastic backing on the edge of theopening near the location of the discrete element.

For comparison, a portion of a film obtained from DelStar Technologies,Inc., Middletown, Del., under the trade designation “DELNET X-550 NAT”was also imaged under the polarization microscope described above. Theapertured film had a hexagonal shaped unit cell including six triangularshaped subcells. It is believed that the aperture film is made by themethod described in U.S. Pat. No. 5,207,962 (Hovis et al.). The filmportion corresponding to one side of each triangle had a higherbirefringence than the other two, with the highest birefringencecentered widthwise and lengthwise. For the film portions correspondingto the other two sides, the birefringence appeared substantially thesame across the width of the film portions.

Example 1

Example 1 was prepared from a film extruded, molded with posts that weresubsequently capped, and stretched in the machine direction according tothe method of Illustrative Example 1. The film was laminated to anelastic carrier obtained from 3M Company, St. Paul, Minn., under thetrade designation “3M WAIST ELASTIC B-430-W” using adhesive obtainedfrom 3M Company under the trade designation “SUPER 77”. A continuousspray coating of the adhesive was used to give a coating level of 5grams per square meter. A piece 2.54 cm by 10 cm was cut from thelaminate and placed between the jaws of a tensile tester obtained fromInstron, Norwood, Mass., under the trade designation “INSTRON 5500R”with 2.54 cm gauge length. The sample was stretched at a speed of 25.4cm (10 inches) per minute to an extension of 5.08 cm (2 inches) in aload range from 3 to 6 lbf (13.3 to 26.7 N). An expansion of the tensileextension vs. load curve is shown in FIG. 7A.

For comparison, a sample was prepared and stretched in the same manneras in Example 1 except not laminated to a carrier. The sample wasstretched at a speed of 2.54 cm (1 inch) per minute to 5.08 cm (2inches) per minute to an extension of 4.19 cm (1.65 inches) with a loadof about 2 lbf (8.9 N). An expansion of the tensile extension vs. loadcurve is shown in FIG. 7B.

Example 2

Example 2 was prepared according to the method of Example 1, except thata portion of the film (5 cm by 10 cm) was laminated to an elasticcarrier obtained from 3M Company under the trade designation “3M FLUTEDELASTIC”. The sample was then stretched by hand. Openings formed onlyover the stretchable portions of the elastic. The resulting laminate hadan appearance similar to that shown in FIG. 5.

This disclosure is not limited to the above-described embodiments but isto be controlled by the limitations set forth in the following claimsand any equivalents thereof. This disclosure may be suitably practicedin the absence of any element not specifically disclosed herein.

What is claimed is:
 1. A laminate comprising an at least partially reticulated thermoplastic film joined to an extensible carrier, the at least partially reticulated thermoplastic film comprising: a thermoplastic backing comprising first and second major surfaces, a plurality of openings in the thermoplastic backing, and a plurality of discrete elements protruding from the first major surface of the thermoplastic backing, wherein there are two discrete elements abutting opposite ends of any given opening, wherein the two discrete elements are aligned in a first direction, wherein there is one discrete element between the given opening and an adjacent opening aligned in a second direction perpendicular to the first direction, wherein each portion of the thermoplastic backing around the given opening is plastically deformed in its lengthwise direction, wherein the carrier comprises a first, extensible zone and a second, non-extensible zone, wherein the first, extensible zone underlies the openings, and wherein the thermoplastic backing overlying the second, non-extensible zone is not reticulated.
 2. The laminate of claim 1, wherein at least some of the discrete elements each comprise one upstanding post.
 3. The laminate of claim 2, wherein the upstanding post is part of a male fastening element.
 4. The laminate of claim 1, wherein at least some of the discrete elements comprise multiple upstanding posts on a surface protrusion.
 5. The laminate of claim 1, wherein the discrete elements have a height above the thermoplastic backing of at least 30 micrometers.
 6. The laminate of claim 1, wherein the thermoplastic backing is substantially planar.
 7. The laminate of claim 1, wherein the plurality of discrete elements are arranged in a staggered array when viewed in the first direction.
 8. The laminate of claim 1, wherein the thermoplastic backing comprises at least one of polyethylene or polypropylene.
 9. The laminate of claim 1, wherein the at least partially reticulated thermoplastic film is bonded to the extensible carrier with adhesive.
 10. The laminate of claim 1, wherein the extensible carrier is non-elastic.
 11. The laminate of claim 1, wherein the extensible carrier is an elastic carrier, and wherein the given opening opens and closes upon extension and retraction of the elastic carrier.
 12. A method of making the laminate of claim 1, the method comprising: providing a thermoplastic backing comprising first and second major surfaces and a plurality of discrete elements protruding from the first major surface of the thermoplastic backing, wherein at least some of the discrete elements are aligned in a row in a first direction; stretching the thermoplastic backing in the first direction to a degree sufficient to plastically deform the thermoplastic backing and separate the at least some of the discrete elements aligned in the row in the first direction, wherein the thermoplastic backing remains intact between the plurality of discrete elements after stretching it in the first direction; laminating the thermoplastic backing to an extensible carrier to provide a laminate, wherein the extensible carrier is extensible in at least a second direction perpendicular to the first direction; and stretching the laminate in the second direction to form a tear in the thermoplastic backing between two adjacent of the discrete elements aligned in the row in the first direction, wherein the tear is interrupted by the two adjacent of the discrete elements, wherein the carrier comprises a first, extensible zone and a second, non-extensible zone, and wherein the tear is formed in the thermoplastic backing where it overlies the first, extensible zone.
 13. The method of claim 12, wherein the extensible carrier is elastic.
 14. The method of claim 12, wherein the extensible carrier is deformed upon stretching in the second direction.
 15. The method of claim 12, wherein after stretching in the second direction, the thermoplastic backing has a thickness that is substantially the same as before stretching in the second direction.
 16. The method of claim 12, wherein laminating the thermoplastic backing to the extensible carrier is carried out before stretching the thermoplastic backing in the first direction.
 17. The method of claim 12, wherein laminating the thermoplastic backing to the extensible carrier is carried out after stretching the thermoplastic backing in the first direction.
 18. The method of claim 12, wherein laminating the thermoplastic backing to the extensible carrier comprises adhering the thermoplastic backing and the extensible carrier together. 